| Export Control Classification | ||
| * Data is subject to the jurisdiction of the Export and Import Controls Bureau of the Department of Foreign Affairs and International Trade of Canada, Department of Commerce of the United States and/or Department of State of the United States. | Regulation | Classification Number |
| Canadian ECL(s)* | ||
| ECCN(s)* | ||
| **Data is not subject to the jurisdiction of the Department of Commerce of the United States or Department of State of the United States but would become subject if exposed to any US involvement. | P-ECCN(s)** | 9E991 |
| USML (ITAR)* | ||
| P-USML** | ||
| Rev. No. | Issue Date |
|---|---|
| 1 | Jun 18/99 |
| 2 | Jul 14/2000 |
| 3 | Oct 20/2000 |
| 4 | Mar 16/2001 |
| 5 | Jun 15/2001 |
| 6 | Sep 21/2001 |
| 7 | Dec 14/2001 |
| 8 | Mar 08/2002 |
| 9 | Jun 14/2002 |
| 10 | Sep 06/2002 |
| 11 | Jan 17/2003 |
| 12 | Apr 11/2003 |
| 13 | Jul 11/2003 |
| 14 | Feb 27/2004 |
| 15 | Apr 23/2004 |
| 16 | Jul 16/2004 |
| 17 | Oct 15/2004 |
| 18 | Jan 21/2005 |
| 19 | May 06/2005 |
| 20 | Aug 12/2005 |
| 21 | Nov 18/2005 |
| 22 | Jun 02/2006 |
| 23 | Mar 16/2007 |
| 24 | Nov 09/2007 |
| 25 | Feb 15/2008 |
| 26 | May 30/2008 |
| 27 | Sep 12/2008 |
| 28 | Nov 28/2008 |
| 29 | Feb 27/2009 |
| 30 | May 29/2009 |
| 31 | Apr 09/2010 |
| 32 | Oct 01/2010 |
| 33 | Dec 02/2011 |
| 34 | Apr 17/2013 |
| 35 | Sep 30/2013 |
| 36 | May 19/2014 |
| P&WC SB No. |
ATA SB No. |
Rev. No. | Engine Model Applicability | Effect/Date Incorporated |
|---|---|---|---|---|
| 25006 | NA | 1 | PW306A | No Effect |
| 25007 | NA | Original | PW306A | No Effect |
| 25010 | NA | Original | PW306A | No Effect |
| 25013 | NA | Original | PW306A | No Effect |
| 25014 | NA | Original | PW306A | No Effect |
| 25015 | NA | Original | PW306A | No Effect |
| 25016 | NA | 3 | PW306A | No Effect |
| 25020 | NA | Original | PW306A | No Effect |
| 25023 | NA | Original | PW306A | Oct 20/00 |
| 25024 | NA | Original | PW306A | No Effect |
| 25026 | NA | 1 | PW306A | No Effect |
| 25030 | NA | Original | PW306A | No Effect |
| 25031 | NA | 1 | PW306A | No Effect |
| 25032 | NA | Original | PW306A | Oct 20/00 |
| 25034 | NA | Original | PW306A | No effect |
| 25035 | NA | Original | PW306A | No Effect |
| 25036 | NA | Original | PW306A | No Effect |
| 25037 | NA | 1 | PW306A | No Effect |
| 25038 | NA | Original | PW306A | No Effect |
| 25039 | NA | Original | PW306A | Nov 09/07 |
| 25040 | NA | Original | PW306A | No Effect |
| 25041 | NA | Original | PW306A | No Effect |
| 25042 | NA | Original | PW306A | No Effect |
| 25043 | NA | 1 | PW306A | No Effect |
| 25047 | NA | Original | PW306A | No Effect |
| 25048 | NA | 1 | PW306A | No Effect |
| 25050 | NA | Original | PW306A | No Effect |
| 25051 | NA | Original | PW306A | No Effect |
| 25053 | NA | 4 | PW306A | No Effect |
| 25054 | NA | 2 | PW306A | No Effect |
| 25057 | NA | Original | PW306A | Oct 20/00 |
| 25058 | NA | 1 | PW306A | Sep 30/03 |
| 25059 | NA | Original | PW306A | No Effect |
| 25060 | NA | Original | PW306A | No Effect |
| 25061 | NA | 2 | PW306A | No Effect |
| 25062 | NA | 1 | PW306A | No Effect |
| 25063 | NA | Original | PW306A | No Effect |
| 25064 | NA | Original | PW306A | Oct 20/00 |
| 25065 | NA | Original | PW306A | No Effect |
| 25066 | NA | Original | PW306A | No Effect |
| 25067 | NA | 1 | PW306A | Oct 20/00 |
| 25068 | NA | Original | PW306A | No Effect |
| 25069 | NA | 1 | PW306A | Oct 20/00 |
| 25072 | NA | 1 | PW306A | No Effect |
| 25073 | NA | Original | PW306A | No Effect |
| 25074 | NA | Original | PW306A | No Effect |
| 25075 | NA | 1 | PW306A | No Effect |
| 25077 | NA | Original | PW306A | No Effect |
| 25079 | NA | 2 | PW306A | No Effect |
| 25081 | NA | Original | PW306a | No Effect |
| 25083 | NA | Original | PW306A | No Effect |
| 25086 | NA | 1 | PW306A | No Effect |
| 25088 | NA | 1 | PW306A | Nov 09/07 |
| 25092 | NA | 1 | PW306A | No Effect |
| 25094 | NA | Original | PW306A | No Effect |
| 25095 | NA | Original | PW306A | Jun 02/06 |
| 25096 | NA | Original | PW306A | No Effect |
| 25097 | NA | 1 | PW306A | No Effect |
| 25100 | NA | Original | PW306A | No Effect |
| 25102 | NA | Original | PW306A | No Effect |
| 25103 | NA | 1 | PW306A | No Effect |
| 25104 | NA | 1 | PW306A | No Effect |
| 25105 | NA | 1 | PW306A | No Effect |
| 25106 | NA | Original | PW306A | No Effect |
| 25107 | NA | Original | PW306A | Nov 09/07 |
| 25108 | NA | Original | PW306A | Apr 23/04 |
| 25111 | NA | Original | PW306A | No Effect |
| 25113 | NA | Original | PW306A | Jan 17/03 |
| 25114 | NA | Original | PW306A | No Effect |
| 25116 | NA | Original | PW306A | No Effect |
| 25117 | NA | 1 | PW306A | No Effect |
| 25118 | NA | Original | PW306A | No Effect |
| 25119 | NA | 1 | PW306A | No Effect |
| 25121 | NA | Original | PW306A | No Effect |
| 25122 | NA | Original | PW306A | Mar 16 2007 |
| 25123 | NA | Original | PW306A | No Effect |
| 25124 | NA | Original | PW306A | No Effect |
| 25125 | NA | Original | PW306A | No Effect |
| 25130 | NA | 2 | PW306A | No Effect |
| 25131 | NA | 1 | PW306A | No Effect |
| 25132 | NA | Original | PW306A | No Effect |
| 25134 | NA | 2 | PW306A | No Effect |
| 25135 | NA | Original | PW306A | No Effect |
| 25136 | NA | Original | PW306A | No Effect |
| 25138 | NA | Original | PW306A | No Effect |
| 25139 | NA | Original | PW306A | No Effect |
| 25140 | NA | 1 | PW306A | No Effect |
| 25141 | NA | 1 | PW306A | No Effect |
| 25142 | NA | Original | PW306A | No Effect |
| 25143 | NA | 1 | PW306A | No Effect |
| 25144 | NA | Original | PW306A | No Effect |
| 25146 | NA | Original | PW306A | No Effect |
| 25148 | NA | Original | PW306A | No Effect |
| 25149 | NA | Original | PW306A | No Effect |
| 25150 | NA | 3 | PW306A | Jan 17/03 |
| 25152 | NA | Original | PW306A | No Effect |
| 25154 | NA | Original | PW306A | No Effect |
| 25156 | NA | 1 | PW306A | No Effect |
| 25157 | NA | Original | PW306A | No Effect |
| 25158 | NA | 2 | PW306A | Jan 17/03 |
| 25159 | NA | Original | PW306A | No Effect |
| 25161 | NA | Original | PW306A | No Effect |
| 25163 | NA | Original | PW306A | No Effect |
| 25164 | NA | 4 | CANCELLED-See SB25206 | No Effect |
| 25166 | NA | Original | PW306A | No Effect |
| 25167 | NA | 2 | PW306A | No Effect |
| 25169 | NA | 2 | PW306A | No Effect |
| 25171 | NA | Original | PW306A | No Effect |
| 25173 | NA | Original | PW306A | No Effect |
| 25175 | NA | Original | PW306A | Mar 16/07 |
| 25177 | NA | 3 | PW306A | No Effect |
| 25178 | NA | Original | PW306A | No Effect |
| 25179 | NA | Original | PW306A | No Effect |
| 25185 | NA | Original | PW306A | June 28/06 |
| 25186 | NA | Original | PW306A | No Effect |
| 25190 | NA | Original | PW306A | No Effect |
| 25191 | NA | Original | PW306A | No Effect |
| 25192 | NA | Original | PW306A | Jul 11/03 |
| 25193 | NA | 1 | PW306A | No Effect |
| 25194 | NA | Original | PW306A | Nov 13/09 |
| 25195 | NA | Original | PW306A | No Effect |
| 25196 | NA | 3 | PW306A | No Effect |
| 25199 | NA | 1 | PW306A | No Effect |
| 25200 | NA | Original | PW306A | No Effect |
| 25201 | NA | 1 | PW306A | No Effect |
| 25203 | NA | 4 | PW306A | Jun 02/06 |
| 25205 | NA | Original | PW306A | No Effect |
| 25206 | NA | Original | PW306A | Nov 09/07 |
| 25207 | NA | 4 | PW306A | Jun 02/06 |
| 25208 | NA | Original | PW306A | No Effect |
| 25211 | NA | 2 | PW306A | No Effect |
| 25212 | NA | Original | PW306A | No Effect |
| 25215 | NA | Original | PW306A | No Effect |
| 25216 | NA | 1 | PW306A | No Effect |
| 25218 | NA | Original | PW306A | No Effect |
| 25222 | NA | Original | PW306A | No Effect |
| 25223 | NA | Original | PW306A | No Effect |
| 25224 | NA | 1 | PW306A | No Effect |
| 25227 | NA | 1 | PW306A | No Effect |
| 25228 | NA | 1 | PW306A | Nov 09/07 |
| 25229 | NA | 4 | PW306A | No Effect |
| 25230 | NA | 3 | PW306A | No Effect |
| 25231 | NA | 1 | PW306A | No Effect |
| 25232 | NA | 1 | PW306A | No Effect |
| 25233 | NA | Original | PW306A | No Effect |
| 25234 | NA | 4 | PW306A | No Effect |
| 25235 | NA | Original | PW306A | No Effect |
| 25236 | NA | Original | PW306A | No Effect |
| 25241 | NA | 1 | PW306A | Jun 02/06 |
| 25245 | NA | Original | PW306A | Jan 21/05 |
| 25246 | NA | 2 | PW306A | No Effect |
| 25247 | NA | 1 | PW306A | No Effect |
| 25249 | NA | 1 | PW306A | No Effect |
| 25250 | NA | Original | PW306A | No Effect |
| 25251 | NA | 1 | PW306A | No Effect |
| 25254 | NA | 1 | PW306A | No Effect |
| 25258 | NA | 2 | PW306A | No Effect |
| 25259 | NA | Original | PW306A | No Effect |
| 25260 | NA | Original | PW306A | Nov 09/07 |
| 25261 | NA | Original | PW306A | No Effect |
| 25264 | NA | 1 | PW306A | No Effect |
| 25265 | NA | Original | PW306A | Apr 09/10 |
| 25267 | NA | Original | PW306A | No Effect |
| 25269 | NA | Original | PW306A | No Effect |
| 25270 | NA | Original | PW306A | Jan 04/08 |
| 25273 | NA | 4 | PW306A | No Effect |
| 25274 | NA | 1 | PW306A | No Effect |
| 25279 | NA | Original | PW306A | No Effect |
| 25280 | NA | 1 | PW306A | No Effect |
| 25281 | NA | 2 | PW306A | No Effect |
| 25282 | NA | 1 | PW306A | No Effect |
| 25286 | NA | 1 | PW306A | No Effect |
| 25288 | NA | 1 | PW306A | No Effect |
| 25290 | NA | Original | PW306A | Feb 15/08 |
| 25291 | NA | 1 | PW306A | No Effect |
| 25293 | NA | 3 | PW306A | No Effect |
| 25295 | NA | Original | PW306A | Feb 15/08 |
| 25297 | NA | 3 | PW306A | No Effect |
| 25298 | NA | 1 | PW306A | No Effect |
| 25299 | NA | Original | PW306A | No Effect |
| 25300 | NA | 1 | PW306A | No Effect |
| 25303 | NA | Original | PW306A | No Effect |
| 25306 | NA | Original | PW306A | No Effect |
| 25310 | NA | Original | PW306A | No Effect |
| 25311 | NA | Original | PW306A | No Effect |
| 25312 | NA | 1 | PW306A | No Effect |
| 25314 | NA | Original | PW306A | No Effect |
| 25315 | NA | 1 | PW306A | No Effect |
| 25316 | NA | Original | PW306A | No Effect |
| 25317 | NA | Original | PW306A | No Effect |
| 25318 | NA | 1 | PW306A | No Effect |
| 25319 | NA | Original | PW306A | May 30/08 |
| 25320 | NA | Original | PW306A | No Effect |
| 25322 | NA | Original | PW306A | No Effect |
| 25323 | NA | Original | PW306A | No Effect |
| 25324 | NA | Original | PW306A | No Effect |
| 25326 | NA | 1 | PW306A | No Effect |
| 25329 | NA | Original | PW306A | Sep 12/08 |
| 25330 | NA | Original | PW306A | Mar 28/08 |
| 25331 | NA | 1 | PW306A | No Effect |
| 25332 | NA | Original | PW306A | No Effect |
| 25333 | NA | Original | PW306A | No Effect |
| 25335 | NA | Original | PW306A | Sep 12/08 |
| 25336 | NA | Original | PW306A | May 30/2008 |
| 25337 | NA | Original | PW306A | Sep 12/08 |
| 25338 | NA | Original | PW306A | No Effect |
| 25339 | NA | Original | PW306A | No Effect |
| 25341 | NA | Original | PW306A | No Effect |
| 25343 | NA | 1 | PW306A | No Effect |
| 25345 | NA | Original | PW306A | Feb 27/2009 |
| 25347 | NA | Original | PW306A | No Effect |
| 25348 | NA | Original | PW306A | No Effect |
| 25349 | NA | Original | PW306A | No Effect |
| 25350 | NA | Original | PW306A | No Effect |
| 25351 | NA | 1 | PW306A | No Effect |
| 25352 | NA | Original | PW306A | No Effect |
| 25355 | NA | Original | PW306A | No Effect |
| 25356 | NA | Original | PW306A | No Effect |
| 25359 | NA | 2 | PW306A | Mar 26/2013 |
| 25360 | NA | 1 | PW306A | No Effect |
| 25361 | NA | 1 | PW306A | No Effect |
| 25364 | NA | 2 | PW306A | No Effect |
| 25365 | NA | 1 | PW306A | No Effect |
| 25366 | NA | 3 | PW306A | No Effect |
| 25367 | NA | Original | PW306A | No Effect |
| 25368 | NA | 1 | PW306A | No Effect |
| 25370 | NA | Original | PW306A | No Effect |
| 25371 | NA | Original | PW306A | No Effect |
| 25372 | NA | Original | PW306A | No Effect |
| 25373 | NA | Original | PW306A | No Effect |
| 25374 | NA | Original | PW306A | No Effect |
| 25375 | NA | Original | PW306A | No Effect |
| 25378 | NA | 1 | PW306A | Mar 26/2013 |
| 25379 | NA | Original | PW306A | No Effect |
| 25382 | NA | 1 | PW306A | Mar 26/2013 |
| 25383 | NA | Original | PW306A | No Effect |
| 25384 | NA | Original | PW306A | Mar 26/2013 |
| 25385 | NA | Original | PW306A | No Effect |
| 25386 | NA | Original | PW306A | No Effect |
| 25387 | NA | Original | PW306A | No Effect |
| 25388 | NA | Original | PW306A | No Effect |
| 25389 | NA | Original | PW306A | No Effect |
| 25390 | NA | Original | PW306A | No Effect |
| 25393 | NA | Original | PW306A | No Effect |
|
Pratt & Whitney Canada
1000 Marie-Victorin Blvd.
Longueuil,
Quebec
Canada
J4G 1A1
Attention: Manager Publications Dept. (05MS1)
FAX: 450-468-7688
Website: www.pwc.ca
Email: customer.service@pwc.ca
|
|
Pratt & Whitney Canada Corp.
1000 Marie-Victorin Blvd.
Longueuil,
Quebec
Canada
J4G 1A1
Attention: Manager - Customer Solutions Large Turbofan Engines
|
|
Pratt & Whitney Canada Corp.
1000 Marie-Victorin Blvd.
Longueuil,
Quebec
Canada
J4G 1A1
Attention: Customer First Center (CFirst)
|
| REF: CFirst (24-hour service) |
| Toll Free - USA and Canada: 1-800-268-8000 |
| Toll Free - International: (International Access Code) + 8000-268-8000 |
| Other: 1-450-647-8000 |
| FAX: 1-450-647-2888 |
| E-mail: CFirst@pwc.ca |
| (1) | Subject matter in this manual is separated into specific Chapters, Sections and Subjects in accordance with ATA Specification No. 100. Each Chapter is divided into sections and each section is divided into subjects. These three elements are shown in large bold numbers at the lower right hand corner of each page, where applicable. Chapters are separated by yellow tab dividers and specific Section/Subjects are separated by green tab dividers. |
| (2) | Chapters contained in this are as follows:
|
| (1) | Chapter 72 is divided into Sections as follows:
|
| (1) | Chapter/Section breakdown for the other Chapters is extensive and is shown in the Table of Contents for each Chapter. |
| (1) | Blocks of page numbers are allocated for different subject topics as follows:
|
| (2) | If a maintenance practice is extensive, the procedure is covered by the more specific page block such as Removal/Installation or Inspection. |
| (1) | Transferred to Para Line Replaceable Units (LRUs) and Check/Servicing Procedures |
| (1) | Transferred to Para Hot Section Inspection |
| (1) | LRUs are any unit that can be readily changed on an aircraft during line maintenance operations. |
| (2) | Check/Servicing procedures include borescope inspection, oil and ignition servicing. |
| BS853 (PW306A) |
| AGB | Accessory Gearbox |
| A/D | Analog to Digital Converter |
| AC | Aircraft |
| A/I | Anti Icing |
| ADC | Air Data Computer |
| AMM | Aircraft Maintenance Manual |
| AMS | Aerospace Material Specification |
| AOG | Aircraft on Ground |
| APR | Automatic Power Recovery |
| ASSY | Assembly |
| ARINC | Aeronautical Radio Incorporated |
| ATA | Air Transportation Association |
| ATTCS | Automatic Take Off Thrust Control System |
| BIT | Binary Digit |
| BITE | Built-in Test Equipment |
| BOV | Bleed-off Valve |
| °C | Degrees Celsius |
| cc | Cubic Centimeters |
| CCW | Counterclockwise |
| CG | Center of Gravity |
| CL | Class |
| CPU | Central Processing Unit |
| CW | Clockwise |
| D/A | Digital to Analogue Converter |
| Dia. | Diameter |
| Dim. | Dimension |
| DPHM | Diagnostics, Prognostics and Health Management |
| ECS | Environment Control System |
| ECTM | Engine Condition Trend Monitoring |
| EDS | Engine Diagnostic System |
| EDU | Engine Diagnostic Unit |
| EEC | Electronic Engine Control |
| EEROM | Electrically Erasable Read Only Memory |
| EGT | Exhaust Gas Temperature |
| F & C | Fits and Clearances |
| °F | Degrees Fahrenheit |
| FADEC | Full Authority Digital Electronic Control |
| FCU | Fuel Control Unit |
| Fig. | Figure |
| FI | Flight Idle |
| FIR | Full Indicator Reading |
| FOD | Foreign Object Damage |
| FSOV | Fuel Shut-off Valve |
| Fwd. | Forward |
| GBS | Ground Based Software |
| GI | Ground Idle |
| GND | Ground |
| HP | High Pressure |
| hr. | Hour |
| HSI | Hot Section Inspection |
| HSR | Hot Section Refurbishment |
| H/W | Hardware |
| ID | Inside Diameter |
| IETM | Interactive Engine Technical Manual |
| IGV | Inlet Guide Vane |
| in. | Inch |
| IPC | Illustrated Parts Catalog |
| kg. | Kilogram |
| kPa | Kilopascals |
| lb. | Pound |
| lb.in. | Pound-inch |
| LE | Leading Edge |
| LH | Left Hand |
| LP | Low Pressure |
| LRU | Line Replaceable Unit |
| LVDT | Linear Variable Differential Transformer |
| Max. | Maximum |
| MCR | Maximum Cruise |
| MCT | Maximum Continuous |
| MFD | Multi Function Display |
| Min. | Minimum |
| mm | Millimeter |
| MOP | Main Oil Pressure |
| MOT | Main Oil Temperature |
| MS | Military Standard |
| msec. | Millisecond |
| MTO | Maximum Take Off |
| N1 | Low-pressure Rotor Speed |
| N1R | Low-pressure Rotor Remote Speed |
| N2 | High-pressure Rotor Speed |
| N2R | High-pressure Rotor Remote Speed |
| N | Newton |
| N.m | Newton-meter |
| OAT | Outside Air Temperature |
| O/C | Open Circuit |
| OD | Outside Diameter |
| O/H | Overhaul |
| O/S | Overspeed |
| oz. | Ounce |
| P1 | Fan Inlet Pressure |
| P2.5 | Compressor Interstage (3rd & 4th) Discharge Pressure |
| P2.8 | Impeller Inlet Pressure |
| P3 | Compressor Discharge Pressure |
| Pamb or PAMB | Ambient Engine Inlet Pressure |
| PAV | Pressure Adjusting Valve |
| P/N | Part Number |
| PMA | Permanent Magnet Alternator |
| PRES | Pressure |
| psi | Pounds per Square Inch |
| psia | Pounds per Square Inch (absolute) |
| psid | Pounds per Square Inch (differential) |
| psig | Pounds per Square Inch (gage) |
| Pt or PT | Engine Inlet Total Pressure |
| PWC | Pratt and Whitney Canada |
| RAM | Random Access Memory |
| Ref. | Reference |
| Repl. | Replacement |
| RES. | Resistance |
| RH | Right Hand |
| ROM | Read Only Memory |
| rpm | Revolutions per Minute |
| RVDT | Rotary Variable Differential Transformer |
| SB | Service Bulletin |
| S/C | Short Circuit |
| sec. | Second |
| SG | Specific Gravity |
| SOL. | Solenoid |
| S/W | Software |
| T4.8 | Inter-turbine Temperature |
| tamb | Ambient Temperature |
| TBA | To Be Advised |
| TBD | To Be Determined |
| TBO | Time Between Overhaul |
| TDC | Top Dead Center |
| Temp | Temperature |
| TLA | Throttle Lever Angle |
| T/R | Thrust Reverser |
| Toil | Oil Temperature |
| TTO | Engine Inlet Total Temperature |
| UART | Universal Asynchronous Receiver and Transmitter |
| UOS | Unless Otherwise Specified |
| U/S | Unserviceable |
| V | Volt |
| VIGV | Variable Inlet Guide Vane |
| 1VS | First-stage Variable Stator |
| W | Watt |
| W/D | Watch Dog |
| WF or Wf | Fuel Flow |
| WOW | Weight on Wheels |
|
Kell-Strom Tool Co. Inc. (CAGE 75245)
214 Church Street
Wethersfield,
CT
06109
USA
TEL: 1-860-529-6851 or 1-860-721-0658 (24 hour service)
Toll free: 1-800-851-6851 (USA & Canada)
FAX: 1-860-257-9694
Website: www.kell-strom.com
|
|
Rasakti Inc. (CAGE 3AD21)
148 Rue Sylvestre
Saint- Germain-De-Grantham,
Quebec
Canada
J0C 1K0
TEL: 1-819-395-1111 (regular & 24 hour service)
Toll free: 1-888-RASAKTI (727-2584) (USA & Canada)
FAX: 1-819-395-1100
Website: www.rasakti.com
Email: I.poirier@rasakti.com
|
|
Pratt & Whitney, Tool Support Services (CAGE 77445)
411 Silver Lane, Mail Stop 129-20
East Hartford,
CT
06118
USA
TEL: 1-860-610-2675 or 1-800-565-0140 or 1-860-565-0140 (24-hour service number)
Toll free: 1-800-PWA-TOOL (792-8665) (USA & Canada)
FAX: 1-860-610-2670
Email: John.lemire@pw.utc.com
|
| Location | Description of Change | Transport Canada Approval Reference |
|---|---|---|
| Table 1 | TR AL-2 incorporated (SB25057, 25064, 25067 and 25069 added and Flight Count Factors for Rotor Drums and Impellers reduced). | Aug 21, 2000 |
| Table 1 | Post-SB25095 (tie-shaft) compressor added. | Nov 21, 2000 |
| Table 1 | Post-SB25096 Impeller added. | Nov 23, 2000 |
| Table 1 | Step added to clarify the calculation of Accumulated Total Cycles when the number of engine starts has not been recorded. Service life equation revised to include Abbreviated Cycle Factor. Compressor Rotor Drum P/N 30B4539-01 deleted from Table. | Feb 16, 2001 |
| Table 1 | Post-SB25104 HP Turbines and Front Cover added to Service Life table. Column added for Abbreviated Cycle Factor. | Apr 30, 2001 |
| Table 1 | Post-SB25135 First-stage HP Compressor Rotor added. | Aug 16, 2001 |
| Table 1 | Flight Count Factor reduced from 1.0 to 0.9 for Rotor Drum Part Nos. 30B4728-01, 30B4746-01 and Impeller 30B4729-01. | Nov 22, 2001 |
| Table 1 | Post-SB25104 second-stage HPT disk P/N 30B5642-01 added. Equation for calculating remaining cycles on modified disks added. | Nov 22, 2001 |
| Table 1 | Total cycles for Fan Hub increased from 6000 to 14000 and Flight Count Factor increased from 1.5 to 1.56. | Mar 05, 2002 |
| Table 1 | Total cycles for LP Turbine Disks increased from 6000 to 15000 and Flight Count Factor increased from 1 to 1.25. | Mar 05, 2002 |
| Table 1 | Total cycles increased for Second, Third and Fourth Stage Compressor Rotors. | 10 February, 2003 |
| Table 1 | To add Post-SB25233 HP Turbine Front Cover to the PW306A Rotor Components - Service Life table. | 04 May, 2004 |
| Table 1 | Added Post-SB25245 3rd- and 4th-Stage LP Turbine Disks, 30A2323 and 30A2324 to the PW306A Rotor Components - Service Life table. | 20 January, 2005 |
| Table 1 | TR AL-4 incorporated. Post-SB25229 HPT first-stage disk and front cover added. | TC approval File No. 5011-E149 (1122641), 23 Mar, 2005 |
| Table 1 | TR AL-4 incorporated. Total cycles for Impellers 30B4796-01 and 30B4860-01 increased from 3000 to 6000 cycles. | TC approval File No. 5011-E84 (1257570), 13 July, 2005 |
| Table 1 | Added Post-SB25331 Fan Hub P/N 30B6767-01 to the PW306A Rotor Components - Service Life table. | 30 May, 2008 |
| Table 1 | Post-SB25319 LPT disks added to Rotor Components - Service Life table: Disk - LP Turbine 3rd stage P/N 30A2343, 4th stage P/N 30A2344 and 5th stage P/N 30A2345. | 30 May, 2008 |
| Page. 1. | The FAA approved maintenance requirement has been introduced. | 06 March, 2013 |
| (2) | Operators shall, as a minimum, record all flights, and accumulated total cycles (which must be calculated) in the applicable document for each component. |
| (3) | The following definitions apply:
|
| (4) | Rotor components must be removed from service when the “total cycle limit” is reached.
Service life is calculated in accordance with the following formula:
|
| (5) | When starts are not recorded, each flight is considered to have been preceded by one engine start, ie. number of starts is equal to the number of flights. |
| (6) | The service life values listed in Table 1 are incorporated in the Type Certificate as issued by Transport Canada. Changes to these values must be approved by Transport Canada. |
| (7) | To calculate the service life remaining, determine the Accumulated Total Cycles and subtract this figure from the applicable total cycles in Table 1. |
| 1. | The total cycles accumulated between each shop visit, rounded to the nearest 100 cycles, must be marked with the last two digits dropped and followed by a dash (-). |
| 2. | Example: A part having cycles between visits of 525, 1819 and 1972 cycles would be marked as CY5-18-20- which equals approximately 4300 total cycles. |
| P/N 30B5642-01 Accumulated Service Life |
= | [ | P/N 30B3972-01 Accumulated Service Life at Modification |
X | ( | LCF Limit for P/N 30B4642-01 | ) | ] | ||
| LCF Limit for P/N 30B3972-01 |
| 1. | Fixed Time Interval Between Overhaul (Fixed TBO) and Hot Section Inspection Fixed TBO and HSI require that engines be overhauled, and that H.S.I.’s be performed, after specific operating interval, as defined in Chapter 05-20-00. |
| 2. | On Condition Maintenance Program The engine is maintained on-wing in accordance with maintenance tasks as defined in the applicable MRB (Maintenance Review Board) document in conjunction with P&WC’s specific recommendations as set forth in Chapter 05-20-00, Table 5. |
| 3. | Operator Specific Maintenance Program. P&WC will work with operators to define specific maintenance programs that are based on a concept of continuous maintenance. Such programs are operator specific, and the program details are the property of the individual operator and P&WC. While P&WC will endorse the resulting program, the operator is responsible for submitting a particular Maintenance Program for approval by the Operator’s local Airworthiness Authority. It must be noted that an Operator Specific Maintenance Program requires an on-going engine sampling program, and are typically relevant to operators of multiple aircraft. |
|
Pratt & Whitney Canada
1000 Marie-Victorin
Longueuil,
Quebec
Canada
J4G 1A1
Attention: Manager
Customer Support PW300 Engines |
| SB25038 | Preformed Packing for Intershaft Seal Housing Transfer Tube - Replacement Of |
| SB25095 | High Pressure Compressor With Tie Shaft - Introduction Of |
| SB25156 | High Pressure Turbine Vane Assembly - Replacement/Modification Of |
| SB25177 | Second Stage High Pressure Compressor Rotor - Replacement/Modification Of |
| SB25203 | Electronic Engine Control - Revised Software |
| SB25195 | Rear Lower Duct Half Assembly - Replacement/Modification Of |
| SB25201 | Preformed Packing For Combustion Chamber Case Drain Valve Adapter - Replacement Of |
| SB25212 | P3 Air Tube Assembly and Flanged Tee Adapter - Replacement Of |
| SB25216 | Outer Combustion Chamber Liner Assembly - Replacement/Modification Of |
| SB25222 | Motive Flow Valve - Replacement Of |
| SB25229 | High Pressure Turbine Disk Balancing Assembly and Vane Assembly - Replacement/Modification Of |
| SB25230 | High Pressure Turbine Disk Balancing Assembly - Replacement Of |
| SB25234 | High Pressure Turbine Vane Assembly - Replacement/Modification Of |
| SB25249 | Fuel Nozzles - Replacement/Modification Of |
| SB25254 | Honeycomb Seal Runner Retaining Ring - Inspection/Crimping Of |
| SB25273 | No. 4 Bearing Carbon Seal And Carrier - Replacement Of |
| SB25279 | P3 Tube Sensing Assembly - Replacement Of |
| SB25294 | Core Cowl Support Brackets - Replacement Of |
| SB25297 | Compressor Bleed Solenoid Valve Support Brackets - Introduction Of |
| SB25303 | Electronic Engine Control - Inspection/Modification Of |
| 1. | A low utilization engine is defined as an engine that has not been subjected to disassembly
and inspection of both hot section and cold section at an approved overhaul facility
by the end of the following service intervals, whichever comes first:
|
| 2. | For engines subjected to low utilization, the recommended initial on-wing Low Utilization
Inspection (LUI) interval is at the end of the following periods:
|
| 3. | Subsequent Low Utilization Inspection (LUI) are to be performed at every 24 months interval, until an overhaul is accomplished. This interval can be increased by 12 months, for scheduling purposes. |
| 4. | For engines that have already accomplished a low utilization inspection before Dec 2012, the first subsequent low utilization inspection is to be accomplished between Jan 2013 and Dec 2015. This interval can be increased by 12 months, for scheduling purposes. The other subsequent low utilization inspections are to be performed in accordance with Para. C. requirements. |
| (1) | In the event of a blue EICAS message indicating FADEC minor fault(s), these faults(s)
can be rectified or the aircraft can be dispatched without immediate maintenance action
under the provisions of Time Limited Dispatch (TLD). If it is elected to dispatch
under the provisions of TLD, it is a requirement that the EDU data be downloaded to
the Ground Based Equipment within 60 hours of the first blue light indication of minor
FADEC fault(s). The downloaded FADEC fault code(s) plus the engine serial number and
total engine time at the point of blue light indication must be reported to P&WC Customer
Support by an acceptable means, including:
|
| (2) | In addition, P&WC must be provided with planned or implemented corrective action as part of the reporting process. |
| (3) | Control system fault(s) other than Minor are to be rectified before the next flight. |
| (1) | Investigate each instance of FOD to determine cause and circumstance. |
| (2) | Inspect cone, fan blades, case and/or inner and outer stators. If defects indicate that a foreign object might have entered the HP compressor, do a borescope inspection of 1st stage IGV and HP compressor blades. |
| (3) | Continue downstream borescoping if indication is found that the foreign object might have affected downstream components. Return engine to an overhaul facility if defects found are not acceptable for continuing in operation. |
| (4) | If damage is acceptable for continuing in operation, rotate the LP rotor by hand and HP rotor with suitable 1/2 inch square drive by installing at centrifugal breather outlet and listen for unusual noise. Return engine to an overhaul facility if unusual noise or roughness is heard. |
| (5) | Inspect chip detector and oil filter. Refer to oil system contamination (Ref. Chapter 72-00-00, FAULT-ISOLATION-1) if debris is found in oil filter or chip detector. |
| (6) | Start engine and ground run. Check that the engine operates normally. |
| (1) | Do the inspection requirements as per Para Steps thru . |
| (2) | Check that the P2.5 and P3 bleed port are free from contamination. |
| (3) | Remove spark igniter (Ref. 74-10-01, IGNITION SYSTEM - MAINTENANCE PRACTICES) and inspect exterior of outer combustor liner for debris through igniter boss (Ref. Fig. ). |
| (4) | Do a fan wash and compressor wash (Ref. 71-00-00, POWER PLANT - CLEANING). |
| (5) | Start the engine and do a ground run. Check that the engine operates normally. |
| (1) | No inspection required. |
| (1) | If there was positive pressure indication during windmilling do an oil level check
before returning the engine to service. If the oil level is low, some oil could be
in the accessory gearbox, therefore, draining the AGB or an engine start might be
required before servicing.
NOTE: If the fuel supply to the engine was cut off during windmilling the fuel pump might
have run dry and need to be replaced as a precaution.
|
| (2) | If there was no positive oil pressure indication:
|
| (14) | If engine was not shutdown, proceed as follows:
|
| (1) | Visually check engine inlet for evidence of arcing, pitting or black scarring, on nose cone or low compressor rotor blades. If evident return engine to an approved overhaul facility. Indicate ligtning strike. |
| (2) | If a lightning strike is suspected but no evidence of arcing is visible, proceed as
follows:
|
| (1) | Return engine to an overhaul facility for an inspection after immersion in water to be carried out in accordance with Overhaul Manual instructions (Ref. Light Overhaul). |
| (1) | Return engine to an overhaul facility for an inspection for dropped engines to be carried out in accordance with Overhaul Manual instructions (Ref. Light Overhaul). |
| (1) | Do a compressor and turbine wash (Ref. 71-00-00, CLEANING). |
| (2) | Drain and refill oil system with new oil (Ref. 72-00-00, SERVICING). |
| (3) | Replace oil filter (Ref. 72-00-00, SERVICING). |
| (4) | Do a borescope inspection of the compressor (Ref. 72-00-00, INSPECTION). |
| (5) | Do a borescope inspection of the HP turbines (Ref. 72-00-00, INSPECTION) and check for glass-like deposits on turbine blades. If found, do a hot section inspection. |
| (6) | Return engine to service if no defects are found. |
| (7) | Drain and refill oil system with new oil (Ref. 72-00-00, SERVICING), 50 ± 10 flight hours after original oil change done at step 2. |
| (1) | Foam, powder or other chemical extinguishers:
|
| (3) | Halon or other fire extinguishing agents listed in Table .
|
| (1) | The engine is designed to withstand landing loads of 6g. If this load was imposed or exceeded during a heavy landing incident, do the checks listed below. |
| (2) | If any of the following defects are evident, replace engine:
|
| (3) | Turn the HP rotor using a suitable hand crank with a 1/2 inch square-drive, installed in the AGB centrifugal breather outlet. Listen for unusual noises which can indicate problems in the accessory gears, bearings, seals and rotors. If unusual noises occur, remove engine for investigation. |
| (4) | Check the following airframe/engine connections for security:
|
| (5) | Check all engine-mounted accessories for security. Rectify if required. |
| (6) | Check for EEC Fault Codes (Ref. 72-00-00, FAULT ISOLATION). |
| (7) | Remove and check oil filter element (Ref. 72-00-00, ENGINE - SERVICING and 79-20-01, OIL FILTER AND HOUSING - MAINTENANCE PRACTICES). |
| (8) | Remove and check chip detector (Ref. 72-00-00, ENGINE - SERVICING and 79-30-01, CHIP DETECTOR - MAINTENANCE PRACTICES). |
| (9) | Do an Engine Performance Check (Ref. 71-00-00, ADJUSTMENT/TEST). |
| (10) | Monitor chip detector fault indication in the cockpit. Check for chip detector fault indication again until 65 flight hours is exceeded. If there is no indication of metal chip, the engine can remain in service with the subsequent inspection as per relevant maintenance program. |
| (11) | Refer to the AMM for additional checks. |
| (1) | Drain and discard oil (Ref. 72-00-00, SERVICING). |
| (2) | Remove and check oil filter (Ref. 72-00-00, SERVICING). |
| (3) | Inspect chip detector (Ref. Chapter 70-00-00, SERVICING). If metallic/magnetic debris is found, return the engine to an overhaul shop. |
| (4) | Rectify cause of high oil temperature (Ref. 72-00-00, FAULT ISOLATION-1). |
| (5) | Fill oil system (Ref. 72-00-00, SERVICING). |
| (6) | In addition continue to inspect the chip detector every 10 flight hours until 65 flight
hours is exceeded. If debris is found, refer to the oil system contamination troubleshooting
charts. (Ref. Chapter 72-00-00, FAULT-ISOLATION-1)
NOTE: This check is not required for aircraft equipped with a functional cockpit chip
detector indicating system. However it is recommended to do an operational check of
the chip detector (Ref. Chapter 79-30-01, MAINT. PRAC.) and the cockpit indicating
system (Ref. AMM) to make sure that the system works correctly . If debris is found,
refer to the oil system contamination troubleshooting charts. (Ref. Chapter 72-00-00,
FAULT-ISOLATION-1)
|
| (1) | If the starter generator fail light comes “ON” during flight and the starter generator
shows external signs of mechanical distress or sheared shaft, it can cause vibrations
which can damage the accessories mounted on the engine and fuel/oil tubes in the surrounding
areas. Do the following checks:
|
| Item No. | Name |
|---|---|
| PWC03-001 | Oil, Engine Lubricating |
| PWC04-001 | Grease, Synthetic |
| PWC05-004 | Acid, Hydrofluoric |
| PWC05-006 | Acid, Phosphoric Concentrated |
| PWC05-009 | Ammonium Bifluoride |
| PWC05-038 | Hydrogen Peroxide, Commercial Grade |
| PWC05-056 | Sodium Hydroxide, Technical Grade |
| PWC05-074 | Acid, Sulfuric |
| PWC05-089 | Lockwire |
| PWC05-195 | Acid, Nitric |
| PWC05-196 | Acid, Hydrochloric |
| PWC05-344 | Cable, Safety Kit |
| PWC06-001 | Compound, Lubricating |
| PWC06-002 | Petrolatum, White |
| PWC06-004 | Compound, Antiseize |
| PWC06-004B | Compound, Antiseize |
| Tool No. | Name | Application |
|---|---|---|
| PWC90025 | Crimper, Safety Cable |
|
| PWC90026 | Test Block, Safety Cable |
| (1) | Reference numbers on “Fits and Clearances”, for applicable chapters, indicate the location of fits, clearances, and parts for which torque and spring pressures are specified. A description of, and limits for, these fits, clearances, torque and spring pressures is located by referring a reference number, given in the text, to the same number given in the appropriate “Fits and Clearances”. In locations where no specific torque limit is given in “Fits and Clearances” the general torque recommendations are specified. |
| (1) | The terms and symbols used in “Fits and Clearances” are explained as follows:
|
| (1) | Torque limits are to be interpreted as follows:
|
| (2) | Unless otherwise specified, thread lubricant shall be engine oil and shall be applied to parts which are to be torqued. |
| (3) | If the part to be tightened is hot, allow sufficient time for the part to reach temperature equilibrium with the surrounding area before final torquing. |
| (4) | Flange bolts shall be drawn up evenly. This can be achieved by having two mechanics working simultaneously 180 degrees apart. |
| (5) | Torque applications should be done slowly and evenly for consistency and the best possible accuracy. |
| (6) | Six-point crowfoot adapters are recommended for applying torque values above 110 lbf. in. (12.4 Nm) to tube fittings (Ref. Fig.). |
| (7) | Check for re-use of self-locking fasteners as follows:
|
| (1) | Check torque indicating devices before using, and calibrate by means of weights and a measured lever arm to make sure that there are no inaccuracies. Checking one torque wrench against another is not sufficient. Some wrenches are quite sensitive to the way they are supported during a tightening operation, and every effort must be made to adhere to the instructions furnished by the respective manufacturers. |
| (1) | Occasionally, it is necessary to use a special extension, or adapter wrench together
with a standard torque wrench (Ref. Fig. ). In order to arrive at the resultant required torque limits, the following formula
shall be used:
LT
A =
LT
L + E
Example:
|
||||||||||||||||||||||||||||||||||||||||||||||
| (1) | All nut, bolt and screw torques should be obtained using a thread lubricant. The lubricant should be engine oil, or equivalent, unless otherwise specified. Torque requirements for interference fit application, such as studs and pipe plugs, may be obtained with or without lubrication, unless otherwise specified. |
| (1) | Antigalling compound (PWC06-001) should be applied to all loose-fit spline drives which are external to the engine and have no other means of lubrication. For certain assembly procedures molybdenum disulfide in either paste form (Type G) (PWC06-004) or powdered form (Type Z) (PWC06-004B) mixed with engine oil (PWC03-001) or grease (PWC04-001) may be used. Particular applications of molybdenum disulfide are indicated in the individual text portions of this manual, as applicable. |
| (1) | Bolts and nuts on flanges with metal tabular gaskets must be initially torqued to the required torque and then retorqued until torque values given in relevant assembly instruction remain constant. |
| (2) | The torque values given within text apply to nuts where the height of the nut is approximately equal to the major diameter of the thread. For jam nuts (Ref. to REMOVAL/INSTALLATION). Values do not apply to hollow bolts and screws. |
| (1) | Where self-locking nuts and helical coil inserts are used, the following procedure
applies:
|
| (1) | When tightening a castellated nut, alignment of slot must be obtained without exceeding the maximum torque. If this is not possible, replace nut with another one. After tightening nut to recommended torque, nut must not be loosened to permit insertion of lockwire or cotterpin. If slot in nut or lockwire hole in bolt or screw is not correctly aligned at the minimum torque value given, the nut, screw or bolt should be further tightened to next alignment position, but maximum torque value given must not be exceeded. Should alignment still be impossible without exceeding maximum torque, back off nut, screw or bolt one-half turn and retorque. |
| (1) | Effective locking of slotted, steel locknuts on bolts or studs requires full engagement of all locknut threads. The chamfered section of the locknut ID does not exert force on the bolt or stud; therefore, it is not necessary that the bolt or stud be flush with, or protrude from, the outer face of the locknut. |
| (1) | When the torque required to drive a stud to the correct protrusion does not reach the minimum value given, or exceeds the maximum value given, a new stud must be selected. |
| (1) | If leakage occurs at a coupling, do not attempt to correct by overtorquing. Disassemble fitting and check for nicks, burrs and/or foreign matter. Use new parts to rectify. |
| (1) | Pre-Assembly Requirements for Cupwashers:
|
| (5) | Assembly Requirements for Cupwashers:
|
| (1) | Retaining rings must be installed using approved retaining ring pliers. Internal type rings must not be compressed beyond the point where the ends of the ring meet. External type rings must be expanded just enough to allow installation without becoming bent. After installation, ensure that each ring is completely seated, without looseness or distortion in its groove. |
| (1) | Except where otherwise specified, the wire is heat and corrosion resistant steel wire of 0.025 inch diameter (PWC05-089). |
| (2) | Basic Rules
|
| (8) | Lockwire Hole Alignment
|
| (10) | Lockwire Twisting
|
| (12) | Lockwire Illustrations
|
| (1) | General:
|
| (7) | Basic Installation Rules:
CAUTION: DO NOT USE SAFETY CABLE IF THE HOLES ARE MORE THAN 0.100 INCH (2.54 mm) DIAMETER.
THE FERRULES ON THE END OF THE CABLE ARE 0.106 - 0.108 INCH (2.69 - 2.74 mm) DIAMETER
AND WILL FALL THROUGH HOLES LARGER THAN THIS.
|
| (22) | Installation (Ref. Fig. )
CAUTION: IT IS IMPORTANT ON THIS FINAL STROKE TO HOLD THE TOOL AS STEADY AND PERPENDICULAR
TO THE CABLE AS POSSIBLE WHILE ENSURING THAT A FULL STROKE IS USED TO MAINTAIN A CONSISTENT
TENSIONING OF THE CABLE.
|
| (34) | Verification (Ref. Fig. )
CAUTION: DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE
SAFETY CABLE TO AVOID DAMAGE TO THE HOLES OF THE PART.
|
| (43) | Indenter Adjustment (Ref. Fig. )
CAUTION: DO NOT ADJUST THE PUSHROD MORE THAN A QUARTER OF A TURN AT A TIME. SEVERE ADJUSTMENTS
MAY DAMAGE THE TOOL.
CAUTION: TIGHTENING THE CRIMP INCREASES REQUIRED HAND FORCES DURING APPLICATION AND INCREASES
CABLE ASSEMBLY TENSILE VALUES. LOOSENING THE CRIMP DECREASES REQUIRED HAND FORCES
DURING APPLICATION AND DECREASES CABLE ASSEMBLY TENSILE VALUES.
|
| (48) | Indenter Calibration (Ref. Fig. )
NOTE: 1. Indenter calibration should be checked periodically and must be checked after
the nose assembly has been removed or interchanged.
NOTE: 2. Do a pull-off load test as often as necessary to make sure the crimp done by
the crimping tool meets the necessary requirements.
|
| (55) | Maintenance of Crimp Cavity:
|
| (1) | When unidentified particles of metal are found, they may be either steel, tin, aluminum, magnesium, silver, bronze, titanium, or cadmium. In some cases the type of metal may be determined by the color and hardness of the pieces. However, when the particles cannot be positively identified by visual inspection and knowledge of the exact character of the metal is desired as an aid to troubleshooting, a few simple tests will determine the kind of metal present. |
| (2) |
The following equipment and chemicals are required to make these tests:
|
| (1) | Steel - the particles of many steels can be isolated by means of the permanent magnet. Magnetic steel or iron is attracted by the magnet. |
| (2) | Magnesium - a simple test for these particles is burning. Magnesium will burn with a bright white flash. |
| (3) | Cadmium - place the remaining particles in the aqueous (water) solution of ammonium nitrate. If all or any of the particles dissolve in this solution, they are cadmium. After this test, rinse and dry any remaining particles. |
| (4) | Tin - the tin particles can be distinguished by their low melting point. With a clean soldering iron, heated to 260°C (500°F) and tinned with 50-50 solder (50 percent tin - 50 percent lead), a tin particle dropped on the iron will melt and fuse with the solder. |
| (5) | Aluminum - when a particle of aluminum is placed in hydrochloric acid, 50 percent by volume, it will fizz with rapid emission of gas bubbles and gradually disintegrate and form a black residue (aluminum chloride). Silver and bronze do not noticeably react with hydrochloric acid. |
| (6) | Aluminum Paint - use this procedure to determine whether or not the material is aluminum
silicone paint, aluminum chips, or silver particles.
|
| (12) | Silver - when a silver particle is placed in nitric acid, it reacts rather slowly, producing a whitish fog in the acid. |
| (13) | Bronze - when a bronze (or copper) particle is placed in nitric acid, a bright green cloud is produced. |
| (1) | Place a piece, or pieces of the metal to be identified, on a white porcelain spot plate. A piece of titanium or titanium-bearing metal should be placed on another spot plate to observe and verify the results obtained. |
| (2) | Add several crystals of ammonium bifluoride and 5 to 10 drops of water to the metal
particles. (Two or three drops of a 5 to 10 percent hydrofluoric acid solution can
be used instead).
NOTE: Solid ammonium bifluoride is crystaline and can be conveniently stored in a dry
area and used as required.
|
| (3) | Let stand 20 to 30 minutes, or until the solution becomes slightly discolored. |
| (4) | Add two or three drops of 1:1 sulfuric acid (one part demineralized water to one part concentrated acid). |
| (5) | Let stand 20 to 30 minutes, or until solution becomes more discolored. |
| (6) | Add three to four drops of 3 to 10 percent hydrogen peroxide. Solution must not be too old. |
| (7) | If titanium is present, a yellowish color will develop. This yellow color will become progressively darker with time, if allowed to set. |
| (8) | Add two to three drops of concentrated phosphoric acid, and stir to discharge any yellow color due to the possible presence of iron. |
| (9) | Any light yellow to orange coloration indicates the presence of titanium. |
| (1) | General
|
| (4) | Applied Marking Methods
CAUTION: DO NOT ELECTROLYTICALLY ETCH ANODIZED SURFACES.
|
| (1) | General
CAUTION: LEAD AND/OR METALLIC PENCILS, OR ANY TEMPORARY MARKING METHOD LEAVING A DETRIMENTAL
DEPOSIT OF CARBON, ZINC, COPPER, LEAD, OR SIMILAR RESIDUE WHICH MAY CAUSE A REDUCTION
IN FATIGUE STRENGTH AS A RESULT OF CARBURIZATION OR INTERGRANULAR ATTACK WHEN THE
PART IS SUBJECTED TO INTENSE HEAT, SHALL NOT BE USED. IN THE EVENT THAT AN UNAUTHORIZED
MARKING MATERIAL IS USED, THE MARK MUST BE THOROUGHLY REMOVED BY A PROCEDURE DICTATED
BY THE MARKING METHOD AND THE PART MATERIAL.
|
| (4) | Applied Marking Methods
CAUTION: ANODIZED SURFACES MUST NOT BE ELECTROLYTICALLY ETCHED.
|
| (8) | Marking Materials, Hot and Cold Section Engine Parts
|
| (15) | Marking Materials, Cold Section Engine Parts Only
|
| (16) | Marking Materials, Hot Section Engine Parts Only. Use layout dye (lightly applied) to mark parts which are directly exposed to engine gas path such as turbine blades and disks, turbine vanes, and combustion chamber liner. |
| (1) |
Prior to installation, new O-ring type preformed packings must be coated with a thin
film of lubricant to the following specifications:
|
| (1) | Remove fittings from engine lines or accessory units. |
| (2) | Remove preformed packings from fittings and discard. |
| (1) | Remove fittings from engine lines or accessory units.
NOTE: Before removal, note angular position of fitting on engine or unit.
|
| (2) | Remove preformed packings, packing retainers (back-up rings) and discard. Discard jam nuts from fittings. |
| (1) | Lubricate new preformed packing with light film of engine oil (PWC03-001) or fluid to be used in line. |
| (2) | Install preformed packing on fitting and screw fitting in boss or flange, as applicable. |
| (3) | Tighten fitting in boss and torque to value detailed in relevant assembly instruction. |
| (4) | Install jam nut on flange mounted fittings and torque jam nut to recommended value (Ref. Table ). |
| (1) | Lubricate new preformed packings, packing retainer (back-up ring) and thread of elbow fitting with light film of petrolatum (PWC06-002) or fluid to be used in the line. |
| (2) | Assemble jam nut, new packing retainer and preformed packing on elbow fitting, pressing packing retainer into counterbore of jam nut. |
| (3) | Turn jam nut down elbow fitting until preformed packing is seated in non-threaded annulus of fitting. |
| (4) | Turn jam nut outward until preformed packing is pushed firmly against first lower thread of fitting. |
| (5) | Install elbow fitting into boss on unit, allowing jam nut to turn with fitting until preformed packing contacts boss mating face. This point will be recognized by increase in torque. |
| (6) | With fitting in this position, hold jam nut stationary and turn elbow fitting into
boss a further 1½ turns.
NOTE: From this position the elbow fitting may be further turned inward to a maximum of
one turn to facilitate alignment of fitting. Should the fitting tighten in the jam
nut before completion of initial 1½ turns or during final alignment, the jam nut may
be allowed to turn with the fitting for the remainder of the distance.
|
| (7) | With elbow fitting in correct alignment position, tighten jam nut and torque to recommended
torque (Ref. Table ).
NOTE: Metal-to-metal contact between jam nut and boss must be obtained without exceeding
recommended torque and there must be no extrusion of preformed packing or packing
retainer.
|
| (1) | Install protective plastic caps on all electrical connectors removed from components or engine (Ref. Fig. ). |
| (1) | Inspect parts for alignment, distortion, foreign matter, looseness, out-of-roundness,
sharp edges, scratches, taper, warping and wear. Additionally, check the following:
|
| (1) | If a micrometer or vernier is to be used, check gage for accuracy before making measurement. Ensure that contacting surfaces are clean and contacting faces of part to be measured are free of dirt and burrs. When using depth gages, ensure anvil is held tight and square against part to be measured. |
| (2) | If a dial indicator is used, ensure indicator base is anchored firmly and that any swivel connections are tightened securely. |
| (3) | When taking measurements with feeler gages, ensure final size of feeler is a reasonably snug fit. |
| (1) | When determining the condition of engine fuel, oil lubrication and pneumatic systems,
removed filters must be inspected for condition and contamination before the application
of any allowable cleaning procedures. Clogged filters could be cause for downstream
low pressure in systems.
NOTE: Other engine components will normally be cleaned prior to carrying out inspection
procedure.
|
| (1) | Inspect weld repair for quality, uniformity, undercutting, cracking and flux removal. Welds must be blended into adjacent metal in gradual, smooth curves. Welds must be sound, clean, free from foreign material, and from internal and external damage which would adversely affect strength of weld. |
| (2) | Nominal welds (those not requiring finishing) must exhibit bead conditions as shown in Figure , detail A. Finished welds must exhibit bead conditions as shown in detail B. |
| (1) | Cracks - Cracked tubing must be replaced. No repair is permitted. |
| (2) | Scratches - Minor scratches having no appreciable depth are acceptable. Scratches to a depth of 0.005 inch must be blended out. Replace tubing with scratches over 0.005 inch deep. |
| (3) | Nicks - Individual nicks up to 0.062 inch long by 0.010 inch wide and 0.003 inch deep can be ignored. Nicks to a maximum depth of 0.005 inch must be blended out to remove sharp edges. Replace tubing with nicks greater than 0.005 inch deep. |
| (4) | Dents - Round bottom dents on straight sections of tubing are permitted provided the length and depth are not greater than 10 percent of the normal outside diameter of tube. No more than one dent to maximum depth per 12 inch length of tube is acceptable. Dents on tube bends, which cause restriction by flattening and local weakening, are not acceptable. |
| (5) | Pitting - Minor isolated pitting up to 0.003 inch deep is acceptable. Clusters of pitting should be blended out to a maximum depth of 0.005 inch. Tubing must be replaced if pitting exceeds 0.005 inch deep. |
| (6) | Corrosion - Staining on tubing and surface corrosion is acceptable if removable by light polishing with crocus cloth and oil. |
| (1) | Inspect components in accordance with the criteria specified in the relevant Chapter/Section/Subject. |
| (2) | Any observed conditions not defined in this manual are not acceptable for repair. |
| (3) | Evaluation of the surface should take into consideration the need for repairs and the limits to which repairs may be made to determine the suitability for continued use of the component. |
| (4) | Unrepairable components shall be quarantined to prevent further use. |
| (5) | It is important to have suitable lighting. The minimum recommended illumination for close and difficult inspection is 100 foot-candles measured at the inspection table top. |
| (6) | Unless otherwise specified, magnification shall not be used. A magnification of 3 to 4X may be used as an aid to evaluate and confirm an observed condition in detail. |
| (1) | Make sure that the work area is clean, prior to engine disassembly. |
| (2) | Benches on which engine parts are placed must be clean and free from grit, metal filings, etc., which may contaminate engine oil systems, fuel systems or hardware. |
| (3) | Clean plastic bags should be available in which oil system and fuel system parts may be stored until ready for re-assembly. |
| (4) | Clean plastic caps or covers should be used to protect exposed tubes or bearing areas. |
| (5) | At re-assembly, make sure that all parts are clean and new preformed packings are installed. |
| (1) | Wear rubber gloves, apron or coveralls and face shield or goggles, when working with solvents. |
| (2) | Use the least toxic of available cleaning materials which will satisfactorily do the work. |
| (3) | Do all cleaning operations in a well ventilated work area. |
| (4) | Make sure that correct and usable fire fighting and safety equipment is conveniently located and available to all personnel. |
| (5) | Do not smoke or expose a flame within 50 feet of cleaning area. |
| (6) | Make sure that all de-greasing agents are fully removed from all parts after cleaning. |
| (7) | Do not use steel brushes for any cleaning operation except when specified within this manual. Use a stiff bristle fiber brush. |
| (1) | Surface to be welded must be free from protective coatings, dirt, grease, oil and other contaminants, and as free as possible from oxide formation. |
| (2) | Wire brushes and abrasives may be used to remove protective coatings and oxides, except that the final step in removing oxides from aluminum alloys should consist of chemical treatment immediately prior to welding. |
| (3) | Wire brushes, when used for cleaning corrosion-resistant alloy, must have bristles of austenitic, corrosion-resistant steel. |
| (4) | No undesirable deposit or residue must remain on surface to be welded after cleaning operation. |
| (1) | Use suction air to remove metal particles on repaired components. |
| (2) | Use a clean soft cloth, dampened with petroleum solvent (PWC11-027) or equivalent to remove polishing compound residue and other foreign material particles. |
| (1) | Use a brush or spray to clean electrical contact pins and connector shell with isopropyl alcohol (PWC11-014). |
| (2) | Dry the connectors with dry, filtered compressed air at 30 psig (207 Kpa) maximum. |
| (3) | Use a spray or brush to apply solvent (PWC11-036) to the electrical contacts. |
| (4) | Connect and disconnect the plug and socket two or three times to clean the contacts. |
| (5) | Use a spray or brush to apply (PWC11-014) or (PWC11-041) to the electrical contact. |
| (6) | Dry the connectors with dry, filtered compressed air at 30 psig (207 Kpa) maximum. |
| (1) | Clean harness connectors (Ref. Para ). |
| (2) | Prepare diluted electrical contact enhancer as follows:
|
| (4) | Put a drop of diluted electrical contact enhancer (PWC05-256) on each connector pin.
NOTE: Let the fluid flow downward on each pin to make a thin film.
|
| Item No. | Name |
|---|---|
| PWC03-001 | Oil, Engine Lubricating |
| PWC05-021 | Cloth, Abrasive Emery |
| PWC05-055 | Sodium Dichromate, Heat-Shrinkable |
| PWC05-057 | Solution, Sodium Hydroxide |
| PWC05-061 | Cloth, Coated Abrasive |
| PWC05-073 | Water, Distilled Deionized or Demineralized |
| PWC05-104 | Pad, Hand Abrasive |
| PWC05-147 | Electrode, 2% Thoriated |
| PWC05-161 | Solution, Touch-Up Chrome Pickle |
| PWC05-162 | Wetting Agent, Chromate |
| PWC05-170 | Compound, Polishing |
| PWC05-195 | Acid, Nitric |
| PWC05-196 | Acid, Hydrochloric |
| PWC05-197 | Acid, Chromic |
| PWC05-198 | Salts, Chromate Conversion |
| PWC05-222 | Paper, Abrasive Aluminum Oxide |
| PWC05-272 | Compound, Polishing |
| PWC05-354 | Tape, Self-Adjusting Insulation Electrical |
| PWC05-419 | Henkel Alodine Magnesium Treatment Kit |
| PWC07-011 | Varnish, Air-Dry |
| PWC07-014 | Varnish, Phenolic Resin, Corrosion Preventative |
| PWC07-016 | Thinner, Surface Sealant |
| PWC07-037 | Touch-up Kit, Surface Sealant |
| PWC07-051 | Base, Primer |
| PWC07-052 | Catalyst, Primer |
| PWC07-053 | Base, Enamel |
| PWC07-054 | Catalyst, Curing Solution |
| PWC07-055 | Thinner, Enamel Base |
| PWC08-016 | Paste, Adhesive, Epoxy |
| PWC08-018A | Paste, Adhesive, (Epoxy) |
| PWC09-002 | Compound, Locking and Retaining |
| PWC11-014 | Alcohol, Isopropyl |
| PWC11-019 | Solution, Chromate Conversion |
| PWC11-027 | Solvent, Petroleum |
| Tool No. | Name |
|---|---|
| PWC31771 | Spreader |
| PWC37517 | Riveter |
| (1) | A tungsten inert gas fusion welding process must be used when repairing cracks in engine parts. Argon or helium gas maybe used in inert gas welding; however, argon is preferred by Pratt & Whitney Canada because its greater density reduces its rate of diffusion with the atmosphere. |
| (2) | Inert gas welding is a gas arc welding process which uses inert gas to protect the weld area from the surrounding atmosphere. The heat necessary for welding is provided by a very intense electric arc which is struck between a non-consumable thoriated tungsten (PWC05-147) (tungsten and thorium alloy) electrode and the metal part. On repairs where a filler material is required, a welding rod, of appropriate material, is fed into the weld area and melted with the base metal in the same manner as in conventional gas welding. |
| (1) | The following equipment is required for the inert gas welding process:
WARNING: IF AN OXYGEN REGULATOR IS USED WITH ARGON GAS, DO NOT REINSTALL REGULATOR ON AN
OXYGEN CYLINDER. ARGON GAS IS NOT FREE FROM OIL AND THE POSSIBILITY EXISTS OF AN
EXPLOSION CAUSED BY PRESENCE OF OIL IN THE REGULATOR.
|
| (1) | Refer to Cleaning. |
| (1) | Welding must be carried out only by certified personnel.
|
| (1) | Blend repair using carborundum stones. |
| (2) | Polish blended area using crocus cloth (PWC05-061). |
| (3) | Blend all repairs and finish smoothly. |
| (4) | Lines, scratches, or sharp edges which may cause a concentration of stress are not permitted. |
| (1) | Remove unserviceable insert using an approved extraction tool. |
| (2) | Clean out hole and ensure swarf and other foreign matter is removed. |
| (3) | Using new helical coil insert, install insert into threaded hole using insert installation tool. Insert outer thread must be between one and one-half threads below surface of hole or counterbore, whichever applies. |
| (4) | Cut off driving tang at notch using approved tang removal tool and remove tang from holes. |
| (5) | Inspect repaired hole. |
| (1) | General
CAUTION: BEFORE INSTALLING NEW STUDS, REFER TO ILLUSTRATED PARTS CATALOG, P&WC P/N 30B1413,
FOR APPROVED LOCATIONS AND PART NUMBERS.
|
| (4) | Replacement of a Damaged Stud
|
| (1) | Ensure damaged hole is suitable for repair in accordance with Subpara. preceding. |
| (2) | Measure core depth of existing hole. |
| (3) | Select relevant size drill and drill hole to depth measured in step , preceding. |
| (4) | Using relevant special tap, thread hole one thread deeper then insert to be fitted. |
| (5) | Where applicable, counterbore hole to required angle and depth. |
| (6) | Clean out hole and ensure freedom from metal chippings and other foreign matter. |
| (7) | If part being repaired is magnesium, treat tapped hole with chrome pickle touch-up
solution (PWC05-161) as follows:
|
| (17) | Using appropriate size helical coil insert, install insert into repaired stud hole (Ref. Para. ). |
| (1) | Equipment Required
|
| (3) | Procedure (Ref. Fig. )
CAUTION: AVOID DAMAGE TO FLANGE.
|
| (1) |
Procedure:
|
| (1) | Definitions:
|
| (2) | Repairs are defined as freehand blending, deburring and/or polishing. It does not include machining or machine grinding. |
| (3) | Perform repairs only on defined damage within the limits specified in the relevant Chapter/Section/Subject. Undefined damage shall render the component unserviceable. |
| (4) | Perform repairs in a direction so that the finishing marks follow the lay of the original manufacturing machining marks. |
| (5) | Restore surface finish of repaired area to the original manufacturing finish. |
| (6) | Make sure repaired area conforms to the original manufacturing shapes, profiles, contours and radii. |
| (7) | Make sure local repairs extend over an area 10 times the depth of damage. |
| (8) | Maintain a smooth transition between repaired areas and adjacent areas. |
| (9) | Make sure repaired area depth is 1/3 deeper than the depth of damage to ensure removal of damage. |
| (10) | Perform visual inspection of all blend repaired components. |
| (1) | Blending:
CAUTION: USE EXTREME CARE TO AVOID OVERHEATING COMPONENTS DURING REPAIR.
|
| (7) | Polishing:
|
| (15) | Buffing:
|
| (17) | Hand Blending Air Gun:
|
| (1) | Use an applicable drill to drill the crimped rivet head on the self-locking-nut side of the bracket. |
| (2) | Use a parallel pin punch to remove the rivet. Remove the self-locking nut plate. |
| (3) | Remove the raised and unwanted material from the holes. |
| (4) | Install a new self-locking nut plate on the bracket. Install rivets. The manufactured head of the rivets must be on the side opposite to the nut on the bracket. |
| (5) | Use a riveter to crimp the rivets. |
| (1) | Drill the crimped rivet head with an applicable drill. |
| (2) | Use a parallel pin punch to remove the rivet. Remove the anchor bolt. |
| (3) | Remove the raised and unwanted material from the holes. |
| (4) | Install a new anchor bolt at the same location and position on the part. Install the rivet. |
| (5) | Use the riveter (PWC37517) or an equivalent tool to crimp the rivet. |
| (1) | Remove jacking insert, with a suitable size drill. |
| (2) | Remove locking compound residue and clean insert seat and associated area, with a wire brush and solvent (PWC11-027). |
| (3) | Coat insert (Ref. IPC) with locking compound (PWC09-002) and install in flange. |
| (4) | To cure compound, locally heat insert to 207 to 217°F (97 to 103°C), with a heat gun for 10 to 15 minutes. |
| (1) | Blending
|
| (11) | To prevent corrosion damage after blending, protect bare magnesium, refer to Para. Subpara. , and |
| (1) | Fill suitable container to 3/4 level with tap water. |
| (2) | Slowly and carefully add required amount of conversion salts (PWC05-198). |
| (3) | Slowly and carefully add required amount of hydrochloric acid (PWC05-196) and stir to mix. |
| (4) | Slowly and carefully add required amount of wetting agent (PWC05-162) and stir to mix. |
| (5) | Fill container to operating level and stir to mix. |
| (6) | Add hydrochloric acid (PWC05-196) or a combination of sodium hydroxide (PWC05-057) and 16 oz of water (PWC05-073) to adjust pH, as necessary. Stir to mix. |
| (1) | Fill container 1/2 full with tap water. |
| (2) | Add sodium dichromate (PWC05-055) slowly and carefully to the water. Stir to dissolve. |
| (3) | Add nitric acid (PWC05-195) slowly and carefully . Stir to mix. |
| (4) | Fill remainder of the container with tap water. Stir to mix. |
| (1) | Clean surface to be repaired using a swab soaked in isopropyl alcohol (PWC11-014) and/or crocus cloth (PWC05-061). |
| (2) | Remove corrosion with any of the following:
|
| (8) | Rinse with clean water at room temperature. |
| (9) | Rinse with clean water heated to 60°C (140°F) minimum). |
| (10) | Dry with clean low pressure compressed air at 200 kPa (29 psig ). |
| (11) | Apply chromate solution (PWC11-019) or chrome pickle solution (PWC05-161) at a temperature of 17 to 29°C (55-85°F) for 30 to 45 seconds to prepared surface,
with a swab or brush. Repeat application frequently to make sure surface is continually
wet with solution during the treatment.
NOTE: Henkel Alodine Magnesium Treatment Kit (PWC05-419) or anodize touch-up pen (PWC05-064B) can be used as an alternative to chrome pickle solution (PWC05-161) or chromate conversion solution (PWC11-019).
|
| (12) | Swab area with clean water until successive swabs are no longer stained yellow. |
| (13) | Dry part in oven or with local heating for 20 to 30 minutes at 85 to 177°C (185-350°F). |
| (14) | Apply surface treatment touch kit (PWC07-037) over corrosion protection surface as follows:
|
| (1) | Treat exposed metal, refer to Para. Sub-para. , and . |
| (2) | Mask area not to be painted. |
| (3) | Apply two coats of epoxy primer (PWC13-001). Wait one hour between the two coats. Allow to air dry at room temperature for eight hours minimum after the second coat. |
| (4) | Apply three coats of aluminized epoxy enamel (PWC05-037). Wait 15 to 30 minutes between each coat. Allow the final coat to air dry at room temperature for 24 hours minimum. |
| (5) | Remove masking and check for full coverage of the exposed area. |
| (1) | Apply varnish (PWC07-011) or (PWC07-014). |
| (1) | Touch-up the bare metal surface as per Para Subpara , and
NOTE: Use an applicable wire brush to remove the remove the remaining corrosion.
|
| (2) | Heat the area locally at 135 ± 14°C (275 ± 25°F) for 20 minutes maximum to remove any moisture. |
| (3) | Allow the part to cool to the room temperature. |
| (4) | Apply epoxy (PWC08-016) or (PWC08-018A) to fill the corroded area. |
| (5) | Heat the area locally at 121 ± 4°C (250 ± 10°F) for 90 minutes. |
| (6) | Remove the epoxy that is above the adjacent surface and polish the area to make the surface smooth. The contour must be the same as it was before the damage. |
| (7) | Touch-up the bare metal surface again as per Para Subpara , and |
|
Technology Energy Corp.
10737 Lexington Drive, P.O. Box 22996
Knoxville,
TN
37932
USA
TEL: 865-671-2003
FAX: 865-675-1241
Website: www.acessystems.com
|
| Tool No. | Name | Application |
|---|---|---|
| PWC38297 | Punch | Alternate to PWC60614 |
| PWC43172 | Puller |
|
| PWC43238 | Riveter |
|
| PWC43239 | Rivet Set |
|
| PWC43240 | Rivet Set |
|
| PWC43430 | Blanking Cover |
|
| PWC43436 | Blanking Cover |
|
| PWC43442 | Velocity Sensor Bracket |
|
| PWC60085 | Rivet Set |
|
| PWC60457 | Pressure Adjustment, Oil Pump |
|
| PWC60614 | Punch | Obsolete - replaced by PW38297 |
| PWC62002 | Fan Hub Protector |
|
| PWC62003 | Riveter |
|
| PWC62004 | Pusher |
|
| PWC62005 | Cutter |
|
| PWC62019 | Split Retaining Ring |
|
| PWC66581 | Fan Wedge |
|
| PWC66645 | Chisel |
| Name |
|---|
| Vibration Analyzer - Model 4040 Viper - 10-100-4040 |
| Vibration Sensor Cable - P/N 10-320-0131 |
| Vibration Sensor Cable - P/N 10-320-0431 |
| G200/ IAI Interface Cable - P/N 10-320-0413 |
| N2 Breakout Splitter - P/N 10-320-0178 |
| Speed Unit - P/N 10-100-0485 |
| Charge Converter Box - P/N 10-100-1500 |
| Optical Probe - P/N 10-100-1773 or P/N 10-100-1300 |
| High Temp. Cable - P/N 10-320-0008 |
| Tacho Probe Cable - P/N 10-320-0126 |
| Optical Probe Bracket - P/N 22-430-0058 or 10-100-0196 |
| USB cable (Connect to notebook running Avtrend) - P/N 10-320-0483 |
| Vibration Sensor - P/N 69-100-0016 |
| (1) | Great care must be taken, when handling or working on turbine powered aircraft, to avoid injury to personnel and damage to property and engine. Areas of extreme danger are the air intake and exhaust jet wake (Ref. Fig. ). |
| (1) | The air intake is capable of generating sufficient suction to pull a person into the intake ducting. The potential danger of this suction cannot be overemphasized; in an idling engine it may be sufficient to cause ingestion of eyeglasses, small tools, rags and small objects in general. |
| (1) | The exhaust jet wake must be approached with extreme caution as extensive damage can be incurred from the high temperature and high velocity gases. At high engine speeds, the jet wake may propel loose dirt, sizeable stones, sand and debris over a considerable distance. The high temperatures in the wake are sufficient to deteriorate asphalt, and for this reason concrete is recommended for run-up areas. |
| (2) | Occasionally, when starting a jet engine, an accumulation of fuel in the exhaust tail pipe is blown out as long streams of flame. Personnel should observe proper fire precautions and move all flammable material to a safe distance. |
| (3) | Exposure to gases in the jet wake should be avoided. Failure to do so may result in respiratory irritations and a burning sensation in the eyes. Particular care should be taken to avoid exposure to gases in confined spaces where the gas concentration may be high. |
| (1) | After engine operation, work that requires contact with the exhaust tailpipe should not be carried out for at least one-half hour. Heat resistant gloves must be worn, should work in this area be required immediately after shutdown. |
| (1) | All jet fuels and lubricating oils have an injurious effect on the skin. Precautions must be taken to avoid contact as much as possible. |
| (1) | Symbols have been designated for the working variables used in connection with engine
testing. The symbols, referenced to various stations within the engine, and their
meaning are described as follows:
|
|||||||||||||||||||||||
| (1) | Instrument accuracy may vary with time. If engine performance numbers change, instrument accuracy should be checked based upon AMM. |
| (1) | Refer to Chapter 5-10-00. |
| (1) | The following information is contained on the trim data plate located on the bottom
of the accessory gearbox.
|
| (14) | Interpret engine data plate information as follows (Ref. Fig. ):
|
| (1) | Refer to Chapter 5-10-00. |
| (1) | Refer to Chapter 5-10-00. |
| (1) | Refer to Chapter 5-50-00. |
| (1) | Refer to Chapter 72-00-00. |
| (1) | Performance checks should not be attempted during moderate to heavy precipitation or fog. Water entering the engine inlet changes the power output of the engine, the change being proportional to the amount of water ingested. Any form of moisture in the air causes the engine to ingest water. This includes occasions when water or snow is blown into the air inlet, or sucked in by the compressor. Freezing rain or slush snow has exactly the same effect on power output as water ingestion and, in addition, may cling to inlet ducts and upset the flow of air to the engine. |
| (1) | Solubility of water in fuel diminishes with reducing temperatures resulting in water fuel separation, with the water tending to accumulate at the lowest level of tank, system or affected component. Further temperature reduction or continued cold soaking of the engine causes formation of ice particles which may partially block the fuel system filters, thus reducing fuel flow. In extreme conditions total blockage of the strainer(s) may occur, indicated by a marked reduction or complete loss of fuel flow to the engine. The application of heat to engine and fuel system components will prevent or remedy such instances. |
| (2) | Similar conditions of ice formation can exist in the engine lubrication system due to condensation in the tank or engine case area. Shutting down of a hot engine in low ambient temperature conditions, followed by a cold soak, will certainly increase the probability of ice formation in both fuel and lubrication systems. |
| (1) | No special precautions or procedures are required for engine starting during hot weather. |
| (1) | Refer to Table for Ground Checks Required Following Major Component Repair/Replacement. |
| (1) | Internal Engine Fire:
|
| (11) | External Engine Fire:
|
| (1) | Thrust Lever Angle (TLA) - CUT OFF or IDLE with CUT OFF switch selected OFF. |
| (2) | Engine Master - ON. |
| (3) | Check EEC fault indication lamps for EEC fault. |
| (4) | Fuel System Shut-off switch - FUEL ON. |
| (5) | Fuel Boost Pump switch - ON. |
| (6) | Fuel Inlet Pressure Indicators - Check normal operating limits (if fitted). |
| (7) | Unnecessary Accessory Loads - OFF. |
| (8) | Cabin Bleed and Anti-icing Systems - OFF. |
| (9) | Motive Flow, if fitted - OFF. |
| (1) | When starting an engine following a normal shutdown, a lock-up of the LP (N1) rotor
may occur because of the different cooling rates of the LP Turbine case and the LP
Turbine assembly. This is acceptable if:
|
| (4) | Ignition - ON or EEC control. For dual ignition exciter system, select single or dual as required. |
| (5) | TLA - IDLE detent or CUTOFF. |
| (6) | Engine Starter Switch - ON. |
| (7) | Monitor ITT and observe that engine accelerates normally to Ground Idle. |
| (8) | Engine Oil Pressure Indicator - Check normal operating limits. |
| (9) |
In the event of Auto Start Abort, proceed as follows:
|
| (1) | TLA - IDLE detent. |
| (2) | TLA - CUT-OFF detent. |
| (1) | Upon initial installation of a new, spare or overhauled engine, a ground calibration run must be carried out. This establishes the installed relationship between N1, N2 and ITT (T4.5). |
| (2) | The curves obtained from the calibration run shall be regarded as masters which must be used to assess engine performance at subsequent ground checks. |
| (3) | Data on engine performance is to be read from cockpit instruments.
NOTE: Engine performance data can also be read from the EEC via an ARINC 429 data bus.
This data can be read by any commercially available ARINC 429 reading device. Additional
engine parameters can also be monitored, thus providing more information to determine
causes of performance changes. Details of the data available via the ARINC bus is
defined in Table . Engine parameters can also be monitored using the Engine Diagnostic System (EDS).
|
| (4) | If N1 is read from an ARINC device or EDS, adjust the values as follows:
|
| (6) | Ground run engine to obtain calibration curves as follows:
CAUTION: ENGINE INLET CONDITIONS CAN BE INFLUENCED BY OBSTACLES AND WIND DIRECTIONS. IF POSSIBLE,
DO THE ENGINE CALIBRATION IN FREE-FIELD INLET CONDITIONS WITH THE ENGINE FACING INTO
THE WIND.
CAUTION: IF THE ENGINE CAN NOT BE LOCATED 50 METERS FROM BUILDINGS AND OBSTACLES, IT IS RECOMMENDED
TO DO A VISUAL INSPECTION OF THE FAN AFTER RUNNING THE ENGINE ABOVE 80% N1.
|
| (16) | Advance thrust lever to the NORMAL TAKE-OFF detent and allow engine to stabilize for three minutes. |
| (17) |
Record the following parameters on Figure as obtained from the cockpit instruments:
NOTE: Record fuel flow from cockpit instrumentation.
|
| (18) | Readjust throttle, and record parameters listed above for each of the conditions defined
in Figure ie:
|
| (20) | Shut down engine on completion of calibration run (Ref. Check No. 3). |
| (21) | Make a copy of Figure and plot N2 Corr and T4.5 Corr against N1 Corr. |
| (22) | If it is not possible to plot the final N1 conditions, due to high or low ambient temperatures, use the four useable conditions only. |
| (23) | If excessive scatter is apparent on plotting the data, rerun the discrepant points. |
| (24) | Keep the graph of the calibration result together with the engine logbook for future reference. |
| (1) | A performance check is to be carried out after completion of work on gas path components or as required by Major Component Repair/Replacement (Ref. Table ). |
| (2) | The procedure to be followed is the same as for Engine Calibration, except data is only required for normal take-off condition. |
| (3) | Plot N2 Corr and T4.5 Corr vs N1 Corr on the existing calibration curves obtained at ground run on initial installation. If the points obtained are within ± 0.5% N2 and ± 10°C T4.5, performance check is satisfactory. |
| (1) | Examples: Ambient Temperature (OAT) = 39°C N1 Speed = 90% T4.5 Obs. = 700°C N2 Obs. = 99% Θ (@39°C) =
39 + 273.15
288.15 = 1.0833√Θ = 1.0408
N1
√Θ =
90
1.0408 = 86.5%
N2
√Θ =
99
1.0408 = 95.1%
T4.5
Θ =
700 + 273.15
1.0833 - 273.15 = 625°C |
|||||||||||||||||||||||||||||
| (1) | Completion of one or more of the following tasks requires complete installation and
adjustment (rigging) of the fuel shut-off cable (Ref. 73-10-05):
|
| (8) | Installation of an engine on an aircraft requires a dimensional check of the fuel shut-off valve tripper sleeve and fuel shut-off cable as described in Chapter 73-10-05. |
| (1) | Starting (P2.8) BOV Operational Check (Ref. Table ):
|
| (21) | Handling (P2.5 and P2.8) BOV Operational Check (Ref. Table ):
|
| (1) | Do the engine ground run checks pre-start, engine start and engine shutdown (Ref. Para. , and ). |
| (2) | Start the engine, run for two minutes or until oil pressure and oil temperature are stabilized. |
| (3) | For AGB seals replacement, run the engine at max. power for two minutes minimum. |
| (4) | Shut down the engine. |
| (5) | Do a visual check for fuel/oil leaks. If there are leaks, correct as necessary and do the leak test again. |
| (1) | Make sure aircraft bleed system is shut-off. |
| (2) | Disconnect the P2.5 and P3 engine cabin bleed ports, on the aircraft side of the engine. |
| (3) | Install a slave LP P2.5 cabin bleed cover (1) and new gasket (2). Install six bolts (4) and torque to 36 to 40 lb.in (4.1-4.5 Nm). |
| (4) | Install a slave P3 cabin bleed cover (5) (PWC43436) and new gasket (6). Install five bolts (8) and torque (Ref. AMM). |
| (5) | Perform engine compressor wash (Ref. 71-00-00, CLEANING) and/or engine performance run, refer to Para. |
| (6) | Remove the slave P2.5 cabin bleed cover (1) and gasket (2) previously installed. |
| (7) | Remove the slave P3 cabin bleed cover (5) (PWC43436) and gasket (6) previously installed. |
| (8) | Install aircraft cabin bleed ports connection on the aircraft side of the engine (Ref. AMM). |
| (1) | The following procedure is used to clear the engine at any time during ground operation
when it is deemed necessary to purge the engine of internally trapped fuel and vapors.
Air passing through the engine serves to remove fuel or vapor from the combustor area,
turbines and engine exhaust nozzle.
|
| (1) | Accomplish prestart Check No. 1. |
| (2) | Ignition Switches - OFF. |
| (3) | Engine Starter Switch - ON. |
| (4) | TLA - IDLE detent. Maintain starter operation for desired duration. Observe starter limits (refer to applicable Starter Manufacturers Manual). |
| (5) | TLA - CUT-OFF or CUT-OFF switch to OFF. |
| (6) | Engine Starter Switch - OFF. |
| (7) | Fuel Boost Pump Switch - OFF. |
| (8) | Fuel System Shut-off Switch - FUEL OFF. |
| (9) | Engine Master Switch - OFF. |
| (10) | Allow starter to cool for specified period, then accomplish a dry motoring run. |
| (1) | TLA - CUT-OFF or IDLE with CUT OFF switch selected OFF. |
| (2) | Engine Master Switch - ON. |
| (3) | Fuel Boost Pump Switch - OFF. |
| (4) | Fuel System Shut-off Switch - OFF. |
| (5) | Engine Starter Switch - ON. |
| (6) | Maintain starter operation for the desired duration. Observe starter limits. (Refer to the applicable Aircraft Flight Manual). |
| (7) | Engine Starter Switch - OFF. |
| (8) | Engine Master Switch - OFF. |
| (9) | Allow the starter to cool before any further starting operation is attempted. |
| (1) | Shut down engine. |
| (2) | Remove two nuts (1) and remove cover (3) using puller (PWC43172). Remove and discard preformed packing (4). |
| (3) | Adjust sleeve (5) using a 7/8 inch open-end wrench, clockwise to increase pressure
or counterclockwise to decrease pressure.
NOTE: One eighth turn (one flat) of the sleeve will change oil pressure approximately
3 psi.
|
| (4) | Install new preformed packing (4) on sleeve (5) and install valve cover (3) on housing with nuts (1). Tighten and torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (5) | Start engine, stabilize at N2=92.8% (25000 RPM or maximum available, whichever is less) for five minutes and check oil pressure (Ref. Fig. ). Repeat procedure as required. |
| (1) | If necessary, adjust oil pressure as follows:
|
| (1) | Refer to Chapter 75-30-04. |
| (1) | Gain access to top area of the LP compressor case/intermediate case (Flange B) and locate the two adjacent nuts at 12 o’clock position. |
| (2) | Remove two nuts (5) and washers (3) from Flange B location. |
| (3) | Install sensor (1) with mounting bracket (PWC43442) (2) with two washers (3) and two nuts (5). |
| (4) | Torque nuts 62 to 72 lbf.in (7.1 - 8.1 Nm). |
| (5) | Install high temperature cable P/N 10-320-0008 connector to vibration sensor P/N 69-100-0016. Torque connector 50 to 60 lbf.in. (5.7 - 6.7 Nm). Connect the other end of the cable to converter box P/N 10-100-1500. |
| (6) | Connect the vibration sensor cable P/N 10-320-0131 to the other receptacle of the converter box and connect the other end of the cable to the VELOCITY receptacle of the Aces Analyzer. |
| (1) | Remove P1/T1 probe from it is mounting point in the inlet cowl and secure to the cowling area. |
| (2) | Install optical tachometer probe P/N 10-100-1773 or P/N 10-100-1300 with bracket P/N 22-430-0058 or P/N 10-100-0196 respectively, on the P1/T1 probe mounting point. |
| (3) | Connect tachometer probe cable P/N 10-320-0126 to the optical probe and the other end to the receptacle marked ‘PHOTO’ on the speed unit P/N 10-100-0485. |
| (1) | Install the vibration sensor (Ref. Para. ). |
| (2) | Install the charge converter box 10-100-0574 with cables 10-320-0431 and 10-320-0008. |
| (3) | Locate the maintenance plate containing the left and right engine maintenance receptacles (Ref. AMM). |
| (4) | Install the G200/IAI interface cable 10-320-0413 and connect to the maintenance connector for the engine under test. |
| (5) | Connect the N1 and N2 cables of the G200/IAI interface cable to the TACH 1 and TACH 2 receptacles, respectively, of the TEC Model 4040 Viper Analyzer, P/N 10-100-4040. |
| (6) | Connect the vibration cable P/N 10-320-0431 to the CHANNEL A receptacle of the TEC Model 4040 Viper Analyzer, P/N 10-100-4040. |
| (1) | Locate the fan blade marked in line with the ‘V’ mark on the inlet cone. Mark a line on the blade platform with an approved silver pencil (PWC05-018). |
| (2) | Clean the area of the inlet cone where the tape is to be attached, with acetone (PWC11-012). |
| (3) | Install a two inch piece of reflective tape (PWC05-238) one inch wide, or two one-half inch wide pieces on the cleaned area fan inlet cone. |
| (4) | Apply a light coat of locking and retaining compound (PWC09-002) around the edges of the tape, and between the two pieces. |
| (5) | Supply power to the analyzer and check that the tachometer triggers when the No. 1 blade is at the 12 o’clock position. |
| (1) | Make sure that the Transient Vibration Survey option is installed in the Viper Analyzer. Detailed instructions are available at the TEC ACES Systems website. |
| (2) | Install the P&WC Transient Vibration Survey setup file in the TEC Model 4040 Viper
Analyzer. Switch the power on and load the procedure into the ACES Analyzer.
NOTE: Make sure that the battery charge indication is more than 80%.
|
| (3) | Determine engine maximum N1% RPM for local pressure altitude and ambient temperature
from the Aircraft Flight Manual.
NOTE: Obtain aircraft and engine information before start of the test. i.e. aircraft registration
number, aircraft hours, engine serial number, hours and cycles.
|
| (4) | Verify and install if required application software 3.05Q and PWC OW setup version
2.72 or greater in the Viper Analyzer. To install this software use notebook computer
10-320-0157, USB cable 10-320-0483, and Avtrend software 10-700-0103. Detailed instructions
are available at the TEC ACES Systems. website: www.acessystems.com/manuals.htm |
| (5) | At the "Main" menu, select the Transient Vibration Survey option with the cursor up/down arrow keys and press ENTER. |
| (6) | At the Transient "Vibration Survey" menu, select Start Job with the up/down arrow keys and press ENTER. |
| (7) | At the "Set-up List" menu, select PW306A OW with the up/down arrow keys and press
ENTER.
NOTE: The screen will display "Loading....Please Wait".
|
| (8) | At the "Job Identification" menu, type in the name of the Customer and Aircraft Serial number with the keypad and press the cursor down key. You can press the F1 “Names” key to select the name from a list if it has previously been used in this analyzer and press ENTER. |
| (9) | Enter the A/C (Aircraft) Registration number with the keypad and press the down arrow key. |
| (10) | Enter the A/C (Aircraft) Total time in hours with the keypad and press ENTER. |
| (11) | At the "Engine Information" menu, select "POSITION 1" for all tests. |
| (12) | Skip over the first section identified as propeller by pressing the cursor down key until the Engine section is reached. |
| (13) | Enter the engine S/N with the keypad or press the F1 "Serial Nos" key to select it
from a list if it has previously been used in the analyzer. Press the down arrow key
to move the cursor into the "Type" field, then with the keypad enter the text 306A.
Press the down arrow key to move the cursor to the "TSO" field and then with the keypad,
enter the engine hours since overhaul. Press the down arrow key to move the cursor
to the "TSN" field and then with the keypad, enter the engine hours since new. Then
press ENTER. There will be a 5-8 second pause while the analyzer initializes the data
acquisition application.
NOTE: The screen will display "Perform FOD check, start the engine, and establish normal
operating conditions".
|
| (14) | Start the engine, let engine stabilize and engine oil temperature reach a minimum
of 125°F (51°C).
NOTE: If required, run the engine at a higher idle speed to warm the engine oil, then
return the power lever to idle.
|
| (15) | When the engine is warmed up and you are ready to begin the survey, press ENTER. |
| (16) | There will be a 10 second delay while the analyzer prepares the Database manager and recovers database memory. When the overall vibration display starts, the analyzer will be recording data. |
| (17) | The Viper screen will display the overall vibration data on the screen, which consists of the following table. |
| (18) | Accelerate engine from idle to target N1 speed identified in item (1), sweep time
approximately 120-180 seconds (between 2 and 3 minutes). When target N1 is achieved,
press ENTER to stop data acquisition.
NOTE: 1. Record Max N1, N2 and ITT values.
NOTE: 2. If N1 target is exceeded by more than 1.5% notify PWC field representative.
|
| (19) | The Viper analyzer will display the message “Store the Data?”. Press the F1 key to answer Yes and save the data, or F5 to answer No if the run is to be deleted. |
| (20) | Decelerate the engine to idle. |
| (21) | Press F5 to continue. |
| (22) | Select the "Manage Job" menu with the upper/lower cursor keys and press ENTER. |
| (23) | Select "Review" with the upper/lower cursor keys and press ENTER. The screen will
display the surveys that are available. Locate the correct survey with the upper/lower
cursor keys and press ENTER.
NOTE: The screen will display the jobs that are available.
|
| (24) | At the "Select Item To Review" menu, select View EN1 vs N1 Vibration with the upper/lower cursor keys and press ENTER. The screen will display the fan vibration plot (Ref. Fig. ). The plot indicates the peak level at the corresponding N1 speed. |
| (25) | Use the Right and Left arrow keys as necessary to locate the highest amplitude peak on the plot. The X (speed) and Y (amplitude) values are displayed in the upper right corner of the analyzer screen. Record the peak amplitude (Y) and RPM (X) value (e.g.: Peak = 0.13@5574.8). |
| (26) | Shut down the engine. |
| (27) | View all the plots from the menu. Transfer the analyzer data to the AvTrend software to print the plots. |
| (28) | Return to "Main" menu by pressing the BACKUP key. |
| (1) | Remove the inlet cone (Ref. 72-30-01). |
| (2) | Record the location of the counterweights on the front balancing rim in the Fan Trim Balancing Data Worksheet (Ref. Fig. ). |
| (3) | Install the inlet cone (Ref. 72-30-01). |
| (4) | Install the optical probe (Ref. Para. ). |
| (5) | Disconnect the N1 speed probe connector from the TEC Model 4040 Viper Analyzer and connect the tacho cable 10-320-0126 connector to the appropriate receptacle of the TEC Model 4040 Viper Analyzer for the N1 speed signal (Ref. Fig. ). |
| (6) | Install reflecting tape on the nose cone (Ref. Para. ). |
| (7) | Power on the Viper analyzer. |
| (8) | At the Main menu, select "Fan/Turbine Balance" with the upper/lower cursor keys and press ENTER. |
| (9) | Select "Start Job" with the upper/lower cursor keys and press ENTER. |
| (10) | At the "Set-up List", select PW306A OW Fan with the upper/lower cursor keys and press ENTER. |
| (11) | At the "Customer Information" menu, type in Customer Name, Aircraft Registration Number and Aircraft Total Time then press ENTER. |
| (12) | At the "Engine Information" menu, select "POSITION 1", then use the upper/lower curser keys to move to "ENGINE". |
| (13) | At the "Engine S/N" field, input "CCXXXX" and press DOWN ARROW KEY. |
| (14) | Input the engine type, time since overhaul (TSO) and time since new (TSN) with the keypad keys and press ENTER. |
| (15) | At the Label Detail Weight Holes menu, input the location of the detail balance weights. Use the up/down cursor keys to select the hole numbers then change the selected hole(s) to an "X" with the right cursor keys. When done, press ENTER. |
| (16) | At the Fan/Turbine Balance Speeds menu, enter the peak vibration speed from the vibration
survey and press ENTER. Start the engine. Let the engine stabilize and oil temperature
reach 125°F (51°C) minimum. Press ENTER.
NOTE: The VIPER Analyzer will prompt Fan/Turbine Balance Setup as a reminder to verify
unit connections. Press ENTER to continue.
|
| (17) | The VIPER Analyzer will display CURRENT RPM VALUE. Press ENTER. |
| (18) |
The VIPER Analyzer will display "Set eng #1 RPM to: XXXX", the peak vibration N1 speed
minus 500. Bring the engine to this speed and press ENTER. At the next display, allow
10 to 15 seconds for the phase and amplitude to stabilize, then press ENTER to accept
the measuring point. Repeat the procedure for the following N1 rpm settings.
|
| (19) | Return the engine to idle speed. |
| (20) | At the "Review Prior Run Data" menu, review data taken and press ENTER. |
| (21) | Shut down the engine and wait as necessary for the optimization of weights to be completed. Press F5 to continue. |
| (22) | Record the position of the counterweight and hole defined by the VIPER Analyzer. |
| (1) | Review the trim balance mass and location solution defined by Viper analyzer in the
two left columns labeled "Hole Suggested".
NOTE: Trim balance counterweight rivet hole locations are counted counterclockwise from
the inlet cone index 'V' mark.
|
| (2) | Install trial counterweight as follows:
|
| (9) | Perform a trial counterweight run as follows:
|
| (14) | If vibration level is within acceptable limits, end the balancing procedure. |
| (15) | If vibration level is not acceptable, record the new counterweight size and location calculated by analyzer. |
| (16) | Remove first trial weight and install solution counterweight (Ref. Para. - Rivet and Counterweight):
NOTE: 1. The analyzer calculates final or successive solutions based on previous trial
counterweight having been removed.
NOTE: 2. Unbalance is corrected by using a maximum of four fan trim counterweights. Existing
fan trim counterweights may be replaced, as required. The weights used for detail
balancing must not be replaced.
NOTE: 3. Maximum of four trim counterweights and four detail counterweights can be added
to the front balancing rim.
|
| (17) | When engine vibration is within acceptable limits, record the counterweight(s) mass and position(s), with respect to fan hub V-mark, in the engine log book. |
| (18) | Remove the test equipment and return the engine to normal operating condition. |
| (1) | Remove the inlet cone (Ref. 72-30-01). |
| (2) | Find the counterweight (6) and rivet (5) to be removed from balancing result. |
| (3) | Remove rivet (5) and counterweight (6) with suitable chisel (PWC66645) and punch (PWC60614) or (PWC38297-101 and PWC38297-102). Remove the flared end of the rivet with the chisel. |
| (4) | Check the hub (2) areas for metal particles and clean as necessary with alcohol (PWC11-014) and dry. |
| (1) | Find the location of the counterweight (6) and rivet (5) in the balance rim (4) as specified from the balancing result. |
| (2) | Install and flare the rivets (5) without the counterweights (6) with riveter (PWC43238) and rivet set (PWC43239) and (PWC43240). |
| (3) | Install and flare the rivets (5) with the counterweights (6) with riveter (PWC43238) and rivet set (PWC60085) and (PWC43240). |
| (1) | Remove the inlet cone (Ref. 72-30-01). |
| (2) |
After removing the inlet cone install the split retaining ring (PWC62019) (8) and secure by tightening holding screw. Always position the split of the retaining
ring at the 6 o'clock position.
NOTE: Blade at 6 o'clock position in line with the split cannot slide forward and disengage
by itself. At other positions blade could slide forward more so at the 12 o'clock
position because the blade slot on the hub slopes downward.
|
| (3) | Install the fan hub protector (4) (PWC62002) on the hub (2) and secure with the inlet cone bolt (3). Torque handtight only. |
| (4) | Close the gap between the bigger outer diameter of the protector (PWC62002) and the hub using a duct tape. This will prevent the ground metal powder from going into and damaging the hub inner diameter. |
| (5) | Find the rivet (7) and counterweight (5) to be removed. Loosen the split retaining ring (8) holding screw and hold the ring in place with one hand while turning the fan hub assembly with the other until the rivet/weight is at 6 o'clock position in line with the split of the ring. |
| (6) | Tighten the split retaining ring (8) holding screw. |
| (7) | Install the fan wedge tool (PWC66581) in between the fan blade tip and the fan case. This will prevent the fan assembly from rotating during the removal and installation of the rivet and counterweight. |
| (8) | Carefully grind the flared side of the rivet (7) using rivet cutter/grinder (PWC62005) - the flared side is on the inside hub diameter where the weight is installed). |
| (9) | The rivet (7) should come out easily. If the rivet does not come off, use pusher (PWC62004) to remove the rivet. |
| (10) | Remove all ground metal powder from the hub. |
| (11) | For removing another rivet/weight repeat steps to . |
| (12) | Remove the inlet cone bolt (3) and the fan hub protector (PWC62002). |
| (13) | Check the inside hub areas for metal particles and clean as necessary. |
| (1) | Clean the hub (2) with alcohol (PWC11-014) and dry. |
| (2) | Make sure the split retaining ring (PWC62019) (8) is installed. |
| (3) | Find the location rivet (7) and counterweight (5) to be install as specified in the balancing result. Loosen the split retaining ring holding screw and hold the ring in place with one hand while turning the fan hub assembly (2) until the rivet/weight is at 6 o'clock position in line with the split of the ring. |
| (4) | Tighten the split retaining ring holding screw. |
| (5) | Position the counterweight from the inside diameter of the hub rim at the location specified in the balancing results. |
| (6) | Secure counterweight with rivet. Flare rivet using riveter (PWC62003). |
| (7) | For installing other rivet (7) and counterweight (5), repeat steps to . |
| (8) | Remove the fan wedge tool (PWC66581). |
| (9) | Carefully remove the split retaining ring (PWC62019) (8). Make sure blades do not slide forward and disengage from the hub. |
| (10) | Install inlet cone (Ref. 72-30-01). |
| Tool No. | Name |
|---|---|
| PWC32677-300 | Engine Wash Rig |
| PWC60708 | Nozzle, Turbine Wash |
| PWC61152 | Nozzle, Compressor Wash |
| PWC62212 | Engine Wash Rig |
| PWC66581 | Fan Blade Wedges |
| (1) | Fresh water external cleaning is recommended when engine is contaminated with salt, volcanic dust or corrosive chemicals such as those found in industrial smog. Demineralized/distilled water is not necessary. The engine must never be left in a contaminated condition overnight, or longer. |
| (2) | If water wash is ineffective, a petroleum solvent (PWC11-027) /water emulsion may be used to remove oil, grime, or other materials/fluids (e.g.
Hydraulic fluids). Thoroughly rinse with water to remove all traces of cleaning fluid.
Completely dry the engine using clean, dry compressed air.
NOTE: External cleaning is very effective in tracing possible origin of external oil leakage.
|
| (1) | Washing removes salt, dirt and other baked-on deposits that accumulate in the gas path and cause engine performance deterioration. |
| (2) | A compressor/turbine desalination wash uses water or water/methanol (PWC11-010) (Ref. Table or Fig. ) to remove salt and light deposits. The addition of cleaning agents is not recommended. |
| (3) | A rinse wash uses the same solution (according to temperature) as the desalination wash (Ref. Table ) and is used after a performance recovery wash to clean the gas path. |
| (4) | A performance recovery wash uses cleaning agents (Ref. Tables , , and ) in the wash solution to remove deposits that cannot be dissolved by a desalination wash. |
| (5) | The formula of the P&WC developed performance recovery solution WCT is shown in Table . |
| (6) | Depending upon the operating environment, the nature and frequency of washing are recommended to be in accordance with Chapter 05-20-00. |
| (1) | Set up engine wash rig (PWC32677-300) as shown on schematic (Ref. Fig.). |
| (2) | Check that the air or nitrogen pressure supply connected to the wash rig is adjusted to 50 psig. |
| (3) | Verify the availability and condition of the wash nozzle assembly (PWC61152) or the Wash Wand.
NOTE: 1. The Wash Wand is a locally designed and fabricated spray nozzle or wand used
to inject wash fluids. Fan Blade wedges (PWC66581) are used to immobilize the fan.
NOTE: 2. The Wash Wand must be designed and fabricated to deliver the recommended amount
of fluid (19 liters or 5 US gallons), at the recommended pressure (50 psi or 345 Kpa),
in the recommended time (20 to 30 seconds) to the core of the engine.
NOTE: 3. The Wash Wand is a hand held tool and should be designed to direct the fluid
stream into the core of the engine while keeping operating personnel at a safe distance
from any rotating parts or splash back and should not present any risk of coming into
contact with rotating parts or of parts liberating and being ingested by the engine.
|
| (1) | Prepare a 5 US Gal. or (10 US Gal. in case of performance recovery) of desalination/rinse solution based on the Outside Air temparature (OAT) of the day in accordance to Table . Use demineralized/distilled water or drinking water quality specified below. |
| (2) | Get a supply of demineralized/distilled water which obeys the criteria that follows:
|
| (8) | Get a supply of drinking quality water complying with the following criteria:
|
| (14) | Depending on the prevailing outside air temperature (OAT), prepare a 5 US Gal. of
performance recovery solution as per Tables , , and using one of the following cleaning agents:
NOTE: Approved solutions for Table are:
NOTE: 1. Approved Recovery Solutions for Table are:
NOTE: 2. The above table results in 5 liters of power recovery solution. Multiply the
5 liters by approximately 4 to obtain 5 U.S. gallons.
NOTE: Approved Biodegradable Solutions for Table are:
|
| (1) | Remove cap assembly (2) from Pt air tube assembly (1). |
| (2) | Remove cap assembly (4) from P3 air tube assembly (3). |
| (3) | Cover two P1/T1 probes in the engine inlet case with suitable waterproof protectors to prevent water from entering the probes. |
| (4) | Disconnect and cap the P2.5 and P3 engine cabin bleed ports, on the aircraft side of the engine (Ref. 71-00-00, POWERPLANT - ADJUSTMENT/TEST). |
| (5) | Make sure throttle is in “CUT-OFF” position. |
| (6) | Make sure ignition system is in the OFF position. |
| (7) | Make sure aircraft bleed system is shut-off. |
| (8) | Set the engine anti-ice switch to “ON” position to prevent the compressor wash fluid from entering the valve piston. |
| (9) | Install compressor wash nozzle assembly (PWC61152) (6, Fig. ) into the engine inlet as follows:
CAUTION: LET A HOT ENGINE COOL FOR 30 MINUTES MINIMUM BEFORE DOING A COMPRESSOR WASH.
CAUTION: DO NOT TIGHTEN THE SUPPORT RODS OF SPRAY NOZZLE TOO MUCH OR DAMAGE TO THE INLET
OR FAN CASE MAY OCCUR.
CAUTION: MAKE SURE THE COMPRESSOR WASH NOZZLE ASSEMBLY (PWC61152) (6) IS SECURELY INSTALLED IN THE INLET CASE.
|
| (17) | Set up for washing operations using alternate tooling, the Wash Wand (described in
Subpara. ) and the fan blade wedges (PWC66581) as follows:
CAUTION: CARE IN INSTALLING THE WEDGES SHOULD BE TAKEN TO AVOID DAMAGE TO THE ABRADABLE LINER.
|
| (1) | Fan blade washing is best accomplished by hand using a sponge or soft clean cloth. Each blade must be washed individually on both pressure and suction side. |
| (1) | Install compressor wash nozzle assembly (PWC61152) and connect to the engine wash rig (PWC32677-300). Check installation per Subpara. |
| (2) | Check the air or nitrogen pressure supply connected to the wash rig is adjusted to 50 psig. |
| (3) |
Do a 30 second dry motoring run. When N2 reaches 5% during acceleration, start injecting
wash fluid. Stop wash fluid injection when N2 drops below 5%. If the wash rig is correctly
adjusted, 5 US Gal. of wash fluid will be used for each motoring run.
NOTE: This is not required when a desalination wash is done.
|
| (4) | Allow cleaning solution to soak for 30 minutes. |
| (5) | Accomplish two 30 seconds dry motoring run, one after the other, and start injecting
rinse solution when N2 reaches 5%. Stop wash fluid injection when N2 drops below 5%.
If the wash rig is correctly adjusted, 5 US Gal. of wash fluid will be used for each
motoring run.
NOTE: Only one motoring run is required for desalination wash.
|
| (6) | Disconnect wash rig (PWC32677-300) and remove compressor wash nozzle assembly (PWC61152). |
| (1) | Do a 30 seconds dry motoring run (Ref. Adjustment/Test). |
| (2) | Install cap (4) on Pt air tube (3). Torque cap 90 to 100 lb.in. (10.0-11.0 Nm) and lockwire (PWC05-089). |
| (3) | Install cap (2) on P3 tube (1). Torque cap 270 to 300 lb.in. (30.0-34.0 Nm) and lockwire (PWC05-089). |
| (4) | Install P1/T1 probe and remove protective covers from P1/T1 sensors in fan case. |
| (5) | Remove all bleed port caps. Allow sufficient time for wash solution to drain. |
| (6) | Reconnect P2.5 and P3 cabin bleed ports. |
| (7) | Do an engine start and run for 3 minutes at GROUND IDLE with CABIN BLEED OFF (Ref. Adjustment/Test). |
| (8) | Shutdown engine. |
| (1) | Remove one igniter plug and install turbine wash nozzle (PWC60708). |
| (2) | Connect engine wash rig (PWC32677-300) to the spray nozzle and adjust air or nitrogen to 50 psig pressure (414 kPa). |
| (3) | Do two 30 seconds dry motoring runs, one after the other, while injecting five gallons of wash fluid (Ref. Table ) at a prescribed rate of 10 gallons per minute. |
| (4) | Remove turbine wash nozzle (PWC60708) and install igniter plug (Ref. 74-10-01). |
| (5) | Do a 30 seconds dry motoring run. |
| (6) | Perform 5 min. engine ground run at ground idle. |
| (1) | Refer to Chapter 05-10-00. |
| (1) | Refer to Table and Figure for leading particulars for engine-driven accessories and accessory drives. |
| (2) | All engine driven accessories, with the exception of the LP rotor speed sensors are mounted on the accessory gearbox and driven by a tower shaft geared to the HP rotor. |
| (3) | All ratios and rpm values are relative to input speeds from the HP rotor and, for
the N1 speed sensor, the LP rotor as follows:
|
| (1) | The fuels specified in Table are recommended by P&WC. Airworthiness authorities normally require operators to follow these recommendations unless alternative fuels have been agreed between the operator and P&WC and approval by the operators airworthiness authority. |
| (2) | The fuels recommended have been substantiated by P&WC specifications and are Transport Canada approved. |
| (3) | The fuel properties specified in Table are the minimum requirements that are accepted for use. As these properties only meet minimum engine requirements, the list is not intended for use as a purchase specification for procurement of fuel for P&WC commercial engines. Rather, it is intended to allow operators to include minimum approved fuel requirements for P&WC engines in conjunction with other functional requirements when formulating their own procurement specification or judging the acceptability of fuels manufactured to other national specifications that exist throughout the world. |
| (4) | Technical requirement tests shall be performed, in accordance with the latest issue of the listed American Society for Testing and Materials (ASTM) test methods. |
| (1) | The Jet Fuel Thermal Oxidation Tester (JFTOT), ASTM D3241, will be used to test thermal
stability. Maximum filter pressure change must be 1.0 inch Hg (25.4 mm Hg) and tube
deposit must be less than Code 3 at the following conditions as defined in ASTM D3241:
|
| (1) | The results from the 500°F (260°C) control temperature test (Ref. Subpara. ), must be reported by the refiner on all fuel analysis reports. |
| (2) | Fuel shall consist solely of hydrocarbon compounds except as otherwise specified herein. It shall be clear and free of undissolved water, sediment, and suspended matter, and shall be suitable for use in aircraft turbine engines. |
| (3) | The odor of the fuel shall not be nauseating or irritating. No substances of known dangerous toxicity under usual conditions of handling and use shall be used. |
| (4) | Fuel that contain dissolved metals is not usable. |
| (1) | One or a combination of the following oxidation inhibitors may be added to the basic
fuel in total concentration not more than 24 mg/l (0.025 g/l) to prevent formation
of gum.
|
| (8) | The following additives in addition to the oxidation inhibitors listed above are acceptable
for use in engine fuel subject to the limitations stated.
|
| (1) | Fuels listed in Table comply with P&WC specifications and are approved for unrestricted use in PW300 engines.
|
| (1) | Refer to 05-20-00, SCHEDULED MAINTENANCE CHECKS for oil drain interval and 72-00-00, SERVICING for oil system servicing. |
| (2) | Major factors affecting oil deterioration over time are engine mechanical condition, climatic, atmospheric and environmental conditions, dust and sand ingestion during take-off/landing modes and engine utilization. |
| (3) | Oil System Servicing
|
| (1) | 5 Centistoke Oils
|
| (3) |
Third Generation Oils
|
| (5) | Other Oils
|
| Name | Number |
| ENGINE - GENERAL | FAULT ISOLATION 1 |
| STARTING PROBLEMS | FAULT ISOLATION 2 |
| OPERATING PROBLEMS-1 | FAULT ISOLATION 3 |
| OPERATING PROBLEMS-2 | FAULT ISOLATION 4 |
| LUBRICATION PROBLEMS | FAULT ISOLATION 5 |
| FADEC FAULT CODES 2 TO 5 | FAULT ISOLATION 6 |
| FADEC FAULT CODES A TO G | FAULT ISOLATION 7 |
| FADEC FAULT CODES H TO P | FAULT ISOLATION 8 |
| FADEC FAULT CODES Q TO Y | FAULT ISOLATION 9 |
| (1) | Table lists the MFD codes with their related faults, and shows if the fault isolation instructions
are found in the engine maintenance manual (EMM), or the aircraft maintenance manual
(AMM), or both.
NOTE: If a QE fault occurance is a result of pilot training or aircraft testing in which
a commanded shutdown in the air is intentional, then no maintenance action is necessary.
|
| (1) | All EEC fault isolation and corrective action procedures are to be done with the aircraft on the ground only. |
| (2) | All resistance values contained within the corrective action procedures are defined to cover an ambient temperature range of -55°C to +80°C. |
| (3) | The resistance of an electrical circuit varies directly as a function of temperature. If a high resistance value is measured for a cold component on a cold day, but is acceptable according to the Fault Isolation Table, it is possible that when the engine is hot, the component resistance will be high enough to cause a fault. |
| (4) | Inspect pin and socket ends for corrosion, contamination or damage when connectors are removed. |
| (5) | All recycling of EEC 28 VDC aircraft power is required with engine(s) not running. |
| (6) | Clean electrical connectors using trichloroethane. |
| (7) | Do all chromel and alumel thermocouple harness checks as follows:
|
||||||||||||||||||||||||||
| (15) | All EEC fault isolation and corrective action procedures are based on treating each fault as a single fault occurrence. |
| (16) | An EEC intermittent fault is a fault which occurs more than once for every two flight legs. |
| (17) | For flight legs with more than one fault occurrence, troubleshoot faults with numerically prefixed MFD fault codes first. |
| (18) | If multiple fault codes occur, check for loose or dirty electrical connectors and rectify as required. Check if fault codes have cleared before proceeding with EEC removal. |
| (19) | Complete the following information sheet and ship with each EEC returned (Ref. Fig. ). |
| (1) | The prefix or first number or letter of each MFD code designation represents a specific LRU. The EEC is designated by LRU codes 1 through 9. Engine interfaces are designated by LRU codes A through N and W. Airframe interfaces are designated by LRU codes P through T and V. |
| (2) | LRU system includes all components which comprise the system, ie: the T45 system includes EEC, main engine harness, rear core harness, junction box and probe harness. |
| (3) | Table lists major code LRU categories. |
| Item No. | Name |
|---|---|
| PWC03-001 | Oil, Engine Lubricating |
| PWC05-063 | Steel, Strapping |
| PWC05-069 | Tape, Pressure Sensitive Adhesive |
| PWC05-070 | Tape, Pressure Sensitive Adhesive |
| PWC05-077 | Oil, Preservative |
| PWC05-089 | Lockwire |
| PWC06-004 | Compound, Antiseize |
| PWC11-027 | Solvent |
| PWC15-011 | Inhibitor, Rust (External Engine Cold Section) |
| PWC15-011A | Inhibitor, Rust (External Engine Cold Section) |
| PWC15-015 | Compound, Corrosion Preventative (Water Displacing) |
| Tool No. | Name | Application |
|---|---|---|
| PWC37728 | Puller |
|
| PWC40453 | Stand, Build | Alternate to PWC66300 |
| PWC43172 | Puller |
|
| PWC60181 | Strap |
|
| PWC61969 | Cable, GBS Download | (See NOTE 1 and NOTE 2) |
| PWC63469 | Bracket, Upper Arm | Replaces PWC60839 |
| PWC63470 | Bracket, Lower Arm | Replaces PWC60838 |
| PWC66103 | Puller |
|
| PWC66106 | Sling |
|
| PWC66300 | Stand | Obsolete - replaced by PWC40453 |
| PWC90191 | Adapter, USB to RS 232 | (See NOTE 1 and NOTE 2) |
|
NOTE: 1. Ref. INTRODUCTION for more details.
|
||
|
NOTE: 2. The cable equipment that is included in the DPHM kit may be purchased separately
through all tooling suppliers.
|
||
| Name | Remarks |
|---|---|
| 3072681, DPHM Kit | (See NOTE) |
|
Pratt & Whitney Canada
1000 Marie-Victorin Blvd.
Longueuil,
Quebec
Canada
J4G 1A1
Attention: Customer Support
|
| (1) | If replacing an oil listed in Table 12 (Ref. Chapter 72-00-00, Description and Operation, Table 12, Approved Lubricating
Oils - PWA521, Type II (5 Centistokes) with another oil also listed in Table 12, continue as follows:
|
| (3) | If replacing an oil listed in Table 12, with an oil listed in Table 13 (Ref. Chapter 72-00-00, Description and Operation, Table 13, Approved Lubricating
Oils - PWA521, Type II (5 Centistokes) “THIRD GENERATION”), or replacing an oil listed in Table 13, with an oil listed in Table 12, continue
as follows:
|
| (11) | If oils of different brands or viscosities are accidentally combined, continue as
follows:
|
| (22) | It is recommended that operators wishing to monitor oil quality, should establish a program in collaboration with their oil supplier/manufacturer. |
| (1) | This dye (PWC05-372) may be added to any P&WC approved lubricating oil on a one time basis when filling the system. The dye improves sight glass visibility and aids in the detection of oil leaks. |
| (2) | Use 0.122 - 0.171 milliliters per liter, or 0.462 - 0.647 milliliters per U.S. gallon of oil. The maximum concentration must not exceed 0.171 milliliters per liter, or 0.647 milliliters per U.S. gallon. |
| (3) | The dye is blue in color, however, when mixed with some oils which are yellow in color, the result may be green colored oil. |
| (1) | Before obtaining an oil sample to analyze, start the engine and run until oil temperature is 70°C (158°F) minimum. Shutdown the engine. |
| (2) | If the Total Acid Number (TAN) is above 2.0, or water content is more than 800 parts
per million, either by weight or by volume, continue as follows:
|
| (1) | Hot Check: Do the oil level check after 10 minutes and within 20 minutes after engine
shutdown, as follows:
|
| (10) | Cold Check: Do the oil level check after more than 20 minutes after engine shutdown,
as follows:
|
| (17) | No Oil Visible: If oil level is not visible in the sight glass oil level indicator
and/or the aircraft has not been used for an extended period, proceed as follows:
|
| (1) | Place suitable containers or drip pan under engine. |
| (2) | Remove oil filler cap. |
| (3) | Remove nuts (11) and washers (12). |
| (4) | Remove cover (13), located on pressure oil pump body, with puller (PWC43172). |
| (5) | Remove and discard preformed packing (10). |
| (6) | On Pre-SB25088 engines, proceed as follows:
CAUTION: DO NOT REMOVE PLUG (14) TO DRAIN THE OIL FROM THE AGB, AS THIS COULD DAMAGE THE
AGB HOUSING.
|
| (9) | On Post-SB25088 engines, proceed as follows:
|
| (1) | Lubricate new preformed packing (10) with engine oil (PWC03-001), install on cover (13) and insert cover into oil pump housing . |
| (2) | Install washers (12) and nuts (11). Torque nuts 23 to 26 lb.in. (2.6-2.9 Nm), two places. |
| (3) | On Pre-SB25088 engines, proceed as follows:
|
| (5) | On Post-SB25088 engines, proceed as follows:
|
| (9) | Remove oil filter cover and withdraw element (Ref. Chapter 79-20-01). |
| (10) | Replace oil filter element if necessary (Ref. Chapter 79-20-01). |
| (11) | Fill cover with specified clean oil, fit new preformed packings and install cover on engine. |
| (12) | Refill oil tank with specified clean oil. |
| (13) | Record the type and brand of oil used in the engine logbook. |
| (14) | Start engine (Ref. Chapter 71-00-00 POWER PLANT - ADJUSTMENT/TEST) and run at stabilized IDLE for fifteen minutes. |
| (1) | If an engine is to be operated with an oil brand or type which differs from that on
which it previously operated, or if the oil system has been contaminated by other
than metallic matter, flush the system as follows:
|
| (1) | Remove chip detector (1) from chip detector valve housing (4) in accessory gearbox.
Remove and discard preformed packings (2 and 3).
NOTE: 1. The chip detector is a two part, self closing type, mounted in an adapter secured
to the accessory gearbox. It is not normally necessary to remove the detector valve
housing (4) and adapter (7). If necessary, remove adapter with puller (PWC37728)
NOTE: 2. Do not clean magnetic plug prior to inspection.
|
| (2) | Inspect the magnetic chip detector (1) and chip detector housing (4) for metal particles.
If metal particles are not present, proceed to step . If metal particles are found, refer to Chapter 79-20-01, Debris in Oil System Inspection.
|
| (1) | Description
|
| (4) | Humidity Control
|
| (7) | Refer to Table for fiberboard shipping container data. |
| (1) | When an engine is to be removed from or installed in a fiberboard container, the
following precautions must be taken:
|
| (1) | Cut and remove strapping (1, Fig. ) from around fiberboard container, retain corners (2) remove cover (3) and sleeve (4) from base (5). |
| (2) | Cut protective envelope (6) and expose top of engine. |
| (3) | Install sling (1, Fig. ) (PWC60248) or (PWC66106), and attach yoke to two lifting brackets (2) at front flange of intermediate case (Flange B). Attach yoke to rear lifting brackets (3), on Flange E. |
| (4) | Lift engine enough to remove four bolts (10) and washers (11), from LH front engine support (12). |
| (5) | Remove cotterpin (9), washer (8) and pin (4) and remove support (12) away from engine. |
| (6) | Remove lockwire and remove quick-release pin (13) from support (18). |
| (7) | Remove lockwire and two quick-release pins (26) from rear supports (20). |
| (8) | Raise engine clear of skid and base assembly. |
| (9) | Remove envelope containing engine log book and relevant records from folding box on skid assembly. |
| (10) | Move skid assembly away from engine. |
| (11) | Remove front RH and LH mount brackets (7 and 19) from intermediate case. |
| (12) | Post-SB25077: Remove safety cover (27). |
| (13) | If engine is to be installed in an aircraft determine if engine is to be LH or RH installation. |
| (14) | Relocate oil filler neck (Ref. Para. ) if necessary. |
| (15) | Relocate engine mounts and mount pad covers (Ref. Para. ) if necessary. |
| (16) | Relocate rear engine mount (Ref. Para. ) if necessary. |
| (1) | Place bags of desiccant and humidity indicator in a suitable oven controlled at 121°C (250°F). The humidity indicator may be removed when an all blue color has been attained. The desiccant bags should remain in the oven for two hours minimum. |
| (2) | Allow oven to cool to room temperature (approximately 22°C (72°F )) and then remove bags and indicator as applicable. |
| (3) | Immediately place desiccant bags in airtight polyethylene envelopes. Exclude all
air and heat-seal envelopes.
NOTE: Desiccant bags must be removed from polyethylene bags prior to installation in shipping/storage
container.
|
| (1) | Ensure that cradle and skid base are serviceable and that a new or serviceable fiberboard sleeve, plywood sides and lid are available. |
| (2) | Make sure that the interior of the protective envelope is fully clean and there is no damage. If necessary, install a new envelope. |
| (3) | Check condition of attaching hardware (if required use new hardware). |
| (4) | Refer to Para. for hoist capacities. |
| (5) | Apply anti-seize compound (PWC06-004) on threads of the bolt (29) that attach the nose cone cover and strap support plate assembly to fan case (Ref. Section F-F). |
| (6) | Install the nose cone cover (28) on the fan case with bolts (29), washers (30) and nuts (31). Torque the bolts (29) 27 to 30 lbf.in. (3.1-3.3 Nm). |
| (7) | Make sure all shipping covers are installed on engine. |
| (8) | Place engine log book, log sheets and other relevant papers to be shipped with engine, in a waterproof envelope and seal with pressure sensitive tape (PWC05-069). Place this material in box and place in shipping container. Secure with pressure sensitive tape. |
| (9) | Raise engine using sling (PWC66106) (1). |
| (10) | Post-SB25077: Make sure safety cover (27) is installed. |
| (11) | Remove LH or RH mount pad cover as applicable, and install LH and RH mount brackets (7 and 19) on intermediate case using four bolts (5) and washers (6) supplied. Tighten 350 to 475 lb.in. (48.0-53.7 Nm) and install lockwire (PWC05-089). |
| (12) | Assemble LH front engine support (12) to LH mount bracket (7) on intermediate case, using pin (4), washer (8) and cotterpin (9). |
| (13) | Install adjustable rods (21) on lugs of exhaust case using pins (24), washers (23) and cotterpins (22). |
| (14) | Install humidity indicator (Ref. IPC) into envelope such that it can be aligned with window in container sleeve. |
| (15) | Lower engine into cradle. |
| (16) | Attach LH front engine support (12) to cradle with four bolts (10) and washers (11). Tighten 720 to 800 lb.in. (80-90 Nm). |
| (17) | Install quick release pin (13) to secure RH front support and install lockwire (PWC05-089). |
| (18) | Adjust length of adjustable rods (21) as necessary to locate in rear engine supports (20). |
| (19) | Verify proper thread engagement of adjustable rods by inserting a piece of lockwire (PWC05-089) into inspection holes. The wire must not pass through. |
| (20) | Tighten nut (25), if rods were adjusted, 275 to 300 lb.in. (32-34 Nm). |
| (21) | Install quick release pins (26) in rear engine supports (20) and install lockwire (PWC05-089). |
| (22) | Disconnect sling from engine. |
| (23) | Tie 12 bags of desiccant (Ref. IPC) to the engine, evenly distributed along length of engine. |
| (24) | Evacuate and heat seal engine envelope. Fold envelope to align humidity indicator (Ref. IPC) with window on fiberboard container. |
| (25) | Install fiberboard sleeve over engine. Close and seal sleeve flaps with pressure sensitive tape (PWC05-070). |
| (26) | Install fiberboard cover and seal with pressure sensitive tape (PWC05-070). |
| (27) | Strap container with two horizontal and three vertical sets of ¾ inch steel strapping (PWC05-063) and fit 20 corners, as applicable. |
| 1. | Customer and/or operator, |
| 2. | Engine type and S/N, |
| 3. | Engine TTSN and TCSN, |
| 4. | Average daily usage before engine preservation, |
| 5. | Geographical area where the engine has operated before preservation, |
| 6. | Type of preservation schedule (If any), |
| 7. | Atmospheric conditions in which the engine was stored (air temperature, relative humidity), |
| 8. | Details on how the engine was preserved or if was not preserved at all, |
| 9. | Elapsed time after engine preservation limit, |
| 10. | Any other information susceptible of determining the condition of the engine. |
| (1) | The following engine preservation schedule lists procedures to be followed:
CAUTION: UNDER NO CIRCUMSTANCES SHOULD PRESERVATIVE OIL BE SPRAYED INTO COMPRESSOR OR TURBINE
ENDS OF ENGINES. DIRT PARTICLES DEPOSITED ON BLADES AND VANES COULD ADHERE AND ALTER
THE AIRFOIL SHAPE, ADVERSELY AFFECTING ENGINE EFFICIENCY.
|
| (7) | Carry out preservation of engine fuel system (engine inactive for more than 28 days)
as follows:
CAUTION: EXTREME CARE MUST BE TAKEN TO PREVENT FOREIGN MATERIAL FROM BEING DRAWN INTO ENGINE
FUEL SYSTEM. EQUIPMENT MUST BE SUPPLIED WITH SUITABLE FILTERS NO COARSER THAN 10
MICRON RATING.
CAUTION: OBSERVE STARTER MOTOR OPERATING LIMITS.
|
| (1) | Depreservation Schedule
|
| (6) | For engines preserved for 91 days and over, replace the following AGB seals.
|
| (7) | Depreservation Procedure
CAUTION: OBSERVE STARTER MOTOR OPERATING LIMITS.
|
| (15) | Do engine ground run checks 1, 2 and 3 (Ref. 71-00-00, POWERPLANT - ADJUSTMENT/TEST).
NOTE: For engine inactive for more than 91 days, run the engine for 25 minutes, starting
with five minutes at idle, followed by five minutes at 80%, five minutes at 70%, five
minutes at 60% and ending with five minutes at idle. Check for oil leakage and oil
consumption.
|
| (1) | For engines installed on aircraft, running the engine once in two weeks (14 days) is an acceptable alternative to avoid the preservation procedure given above. This prevents stagnation of fuel in the fuel system, reduces humidity and condensation accumulation in the oil system. |
| (2) | For engines installed on aircraft, running the engine every 28 days for period of
six month or more will require the following maintenance activities before returning
to active services.
|
| (1) | If engine will be inactive for 29 to 90 days, or is being sent for overhaul, preserve
fuel system (Ref. Para. ).
NOTE: If engine is being removed for installation into another aircraft, or moved from
one side of an aircraft to the other, fuel system preservation is not necessary.
|
| (2) | Drain oil system (Ref. Para. ). |
| (3) | Download EDU data with GBS cable (PWC61969), PW30X Transfer Module P/N 30B2977 (Ref. 77-40-01, ENGINE DIAGNOSTIC UNIT (EDU) - MAINTENANCE PRACTICES). |
| (4) | Remove the powerplant from the airframe (Ref. AMM). |
| (5) | Remove equipment from engine (Ref. AMM). |
| (6) | Install engine in storage container (Ref. Para. ) or maintenance stand (Ref Para. ) as applicable. |
| (7) | If engine is being stored in a container, complete preservation according to preservation schedule (Ref. Para. ) |
| (1) | Remove engine from storage container (Ref. Para. ) or maintenance stand (Ref Para. ) as applicable. |
| (2) | Build up powerplant (Ref. AMM). |
| (3) | Install powerplant in airframe (Ref. AMM). |
| (4) | Depreserve engine fuel system (Ref. Para. ) if necessary.
NOTE: If engine was removed for installation into another aircraft, or moved from one
side of an aircraft to the other, fuel system depreservation is not necessary.
|
| (5) | Load aircraft S/N and engine position, LH or RH, into EDU with GBS cable. |
| (6) | Do engine checks 1, 2 and 3. |
| (7) | Check engine oil level and replenish as necessary (Ref. Para. ). |
| (8) | Check engine for oil and fuel leaks. |
| (9) | Do engine Check No. 4 (Ref. Chapter 71-00-00, ADJUSTMENT/TEST). |
| (1) | Install sling (PWC66106), straps (PWC60181) and chain hoist on the engine and take up the weight. |
| (2) | Remove four bolts (4) from lower support bracket (PWC63470) and four bolts (5) from upper support bracket (PWC63469) and remove the engine. |
| (3) | If engine is to be installed in an aircraft determine if engine is to be LH or RH installation. |
| (4) | Relocate oil filler neck (Ref. Para. ) if necessary. |
| (5) | Relocate engine mounts and mount pad covers (Ref. Para. ) if necessary. |
| (6) | Relocate rear engine mount (Ref. Para. ) if necessary. |
| (1) | Make sure the wheels on stand (1) (PWC66300) or (PWC40453) are locked. |
| (2) |
Lift the engine with sling (PWC66106), straps (PWC60181) and chain hoist and position on maintenance stand (1) (PWC66300) or (PWC40453).
NOTE: Bolts (6 and 7) on support brackets (2) and (3) must be finger tight.
|
| (3) | Install lower support bracket (2) (PWC63470) with four bolts (4). Tighten finger tight. |
| (4) | Install upper support bracket (3) (PWC63469) with four bolts (5). Tighten finger tight. |
| (5) | Torque bolts (4, 5, 6 and 7) 275 to 300 lb.in. (31-33 Nm). |
| (6) | Remove the sling. |
| (1) | Drain oil (Ref. Para. , ) until it is below level of filler neck connection at intermediate case. |
| (2) | Remove tube coupling nuts from elbow (1). |
| (3) | Remove bolts (5) fastening the vent tube (2) to the pressure indicator housing (7). |
| (4) | Remove nut (32) and bolt (4), fastening loop clamp (3) to bracket (30). |
| (5) | Remove vent tube (2). Remove and discard preformed packing (6). |
| (6) | Remove filler cap (10). Remove and discard preformed packing (11). |
| (7) | Remove nut (31), bracket (30), washer (29) and bolt (28) from flange C. Remove nut, washers and bolt from similar location on the other side of the engine, approximately 1 o'clock, and install in hole vacated by removal of bolt (28). Torque nut 27 to 30 lb.in. (3.1-3.4 Nm). |
| (8) | Remove bolt (9) fastening bracket (8) and pressure indicator housing (7) to flange. Remove bolt and washer from similar location, approximately 2 o'clock, on other side of the engine, and install bolt and washer in hole vacated by removal of bolt (9). Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (9) | Pre-SB25164 or Pre-SB25206:
|
| (12) | Post-SB25164 or Post-SB25206:
|
| (17) | Remove bolts (22) fastening bottom of filler neck (14) to case. |
| (18) | Pre-SB25164 or Pre-SB25206: Remove bolts (16) and bracket (15). Remove filler neck (14). |
| (19) | Post-SB25164 or Post-SB25206: Remove bolts (16), bracket (15) and bracket (35). Remove filler neck (14). |
| (20) | Remove bolts (19), washers (18) and blanking plate (17) from the similar location on the other side of the engine, approximately 3 o'clock, and install in spot vacated by removal of filler neck (14). |
| (21) | Remove bolts (24), washers (25) and cover (26) from the similar location on other side of the engine, at approximately 5 o'clock. Remove and discard preformed packing (27). |
| (22) | Lubricate new preformed packing (27) with engine oil (PWC03-001), and install on cover (26). |
| (23) | Install cover (26) with washers (25) and bolts (24), in spot, approximately 8 o'clock, vacated by removal of filler neck. Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (24) | Pre-SB25164 or Pre-SB25206:
|
| (28) | Post-SB25164 or Post-SB25206:
|
| (34) | Position bracket (8) and pressure indicator housing (7) on flange C with bolt (9). Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (35) | Lubricate new preformed packing (6) with engine oil (PWC03-001), install on vent tube (2) and install tube on the pressure indicator housing (7) with two bolts (5). Torque bolts (5) 24 to 36 lb.in. (2.7-4.1 Nm). |
| (36) | Pre-SB25164 or Pre-SB25206: Torque bolts (13) 24 to 36 lb.in. (2.7-4.1 Nm). |
| (37) | Post-SB25164 or Post-SB25206: Torque bolts (5, 37 and 41) to 36 - 40 lb.in. (4.1-4.5 Nm). |
| (38) | Lubricate preformed packing (11) with engine oil (PWC03-001) and install on filler cap (10). |
| (39) | Install filler cap (10). |
| (40) | Install elbow (1) on tube, and reposition to connect vent tube (2) . Torque coupling nuts 90 to 100 lb.in. (10-11 Nm) and install lockwire (PWC05-089). |
| (41) | Install bracket (30) on flange C, approximately 1 o'clock, with bolt (28), washer (29) under head, and nut (31). Torque nut 27 to 30 lb.in. (3.1-3.4 Nm). |
| (42) | If removed, install loop clamp (3) on vent tube (2), and fasten to bracket (30) with bolt (4) and nut (32). Torque nut 27 to 30 lb.in. (3.1-3.4 Nm). |
| (43) | Loosen bolts (21), and turn oil level sensor (20) approximately 25° to rear. Lubricate bolts (21) with engine oil (PWC03-001). Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (44) | Replenish oil (Ref. Para. , ) |
| (1) | Remove engine mounts from the one and four o'clock position, RH side or the ten and eight o'clock position, LH side, as applicable (Ref. Aircraft Maintenance Manual). |
| (2) | Remove bolts (3), washers (2) and mount pad covers (1) from the one and four o'clock position, RH side or the ten and eight o'clock position, LH side as applicable. |
| (3) | Install engine mounts at the one and four o'clock position or the ten and eight o'clock position as applicable (Ref. Aircraft Maintenance Manual). |
| (4) | Lubricate bolts (3) with engine oil (PWC03-001). |
| (5) | Install mount pad covers (1) with washers (2) and bolts (3) at the one and four o'clock positions, or the ten and eight o'clock positions as applicable. |
| (6) | Torque bolts (3) 36 to 40 lb. in., eight places, LH side or RH side, as applicable |
| (1) | Relocate the rear engine mount in accordance with Removal/Installation procedure (Ref. 72-70-01, MAINTENANCE PRACTICES). |
| Item No. | Name |
|---|---|
| PWC06-009 | Antiseize Compound |
| Tool No. | Name |
|---|---|
| PWC37711 | Kit, Borescope |
| PWC43685 | Guide Tube |
| PWC61803 | Guide Tube |
| PWC62363 | Guide Tube |
| Name |
|---|
| Everest Digital Borescope - Model PXDL-515 (or equivalent from another manufacturer) |
| or |
| Everest Digital Borescope - Model PXDL-420 (or equivalent from another manufacturer) |
| Side Viewing Lens - P/N PXT480SG (or equivalent from another manufacturer) |
| (1) | The HSI procedure is broken down into major tasks as listed below. The tasks are arranged in accordance with the A.T.A.100 Chapter/Section/Subject numbering system and correspond with the same numbering system in the Illustrated Parts Catalog. Special tools and consumable materials required to do each major task are listed with the appropriate section. |
| (2) | Inspection criteria for individual components which have been removed from the engine are provided in these sections. Refer to Borescope Inspection for inspection criteria of the complete engine. |
| (1) | Disconnect No. 4 bearing pressure and scavenge oil tubes from exhaust case (Ref. 79-20-03 and 79-20-04). |
| (2) | Disconnect emergency fuel shut-off cable (Ref. 73-10-05). |
| (3) | Disconnect and remove T4.5 “IN” wiring harness connections from N1/T4.5 terminal box (Ref. 77-20-01). |
| (4) | Remove exhaust case (Ref. 72-50-03). |
| (5) | Remove LP turbine module (Ref. 72-50-02). |
| (6) | Remove HP turbines (Ref. 72-50-01).
NOTE: The first and second-stage HP turbines comprise a balanced assembly. Rejection of
either turbine requires that both be returned to an approved overhaul facility for
refurbishment and rebalancing, as required.
|
| (7) | Remove the first-stage HP turbine vane (Ref. 72-40-01). |
| (8) | Visually inspect the combustion chamber outer case and liner. Remove only if required by the inspection criteria. |
| (1) | Assemble acceptable or replaced hot section components in accordance with the appropriate Chapter/Section/Subject. |
| (2) | Install combustion chamber outer case and liner (Ref. 72-40-01). |
| (3) | Install HP turbine (Ref. 72-50-01). |
| (4) | Install LP turbine module (Ref. 72-50-02). |
| (5) | Install exhaust case (Ref. 72-50-03). |
| (6) | Install T4.5 “IN” wiring harness connections on N1/T4.5 terminal box (Ref. 77-20-01). |
| (7) | Install No. 4 bearing pressure and scavenge oil tubes on exhaust case (Ref. 79-20-03 and 79-20-04). |
| (8) | Connect N1 speed probe wiring harness to N1/T4.5 terminal box (Ref. 77-20-01). |
| (9) | Install and rig emergency fuel shut-off cable (Ref. 73-10-05). |
| (10) | Service oil system if necessary (Ref. 72-00-00, SERVICING). |
| (11) | Perform required ground checks (Ref. 71-00-00 ADJUSTMENT/TEST). |
| (1) | The borescope is an optical device that enables an operator to perform visual inspections of the hot section and compressor areas of the engine while the engine remains installed in the airframe or at a ground handling installation, as applicable. |
| (2) | The borescope equipment has the capability to take and store digital photographs on removable media so that a record may be made of the borescope inspection. |
| (3) | Damage may be difficult to estimate through a borescope. It is therefore important that borescope inspection be performed by experienced personnel only. |
| (4) | It is recommended that a compressor wash be performed (Ref. 71-00-00) prior to carrying out a borescope inspection. |
| (5) | Rotation of the HP compressor and HP turbine for borescope inspection and AGB static
torque check can be done by removing the AGB centrifugal breather outlet and installing
a suitable hand crank with a ½ inch square drive.
NOTE: For AGB static torque check, use a standard torque wrench with ½ inch square drive.
|
| (6) | Borescope access to engine components can be achieved as outlined in Table , following: |
| (1) | Remove accessory gearbox breather tube (Ref. Airframe Maintenance Manual). |
| (2) | Insert borescope probe through fan and core stators until VIGV is visible. |
| (3) | Inspect VIGV. |
| (4) | Reposition probe (Ref. Step and ) until all 29 vanes have been inspected. |
| (5) | Remove borescope. |
| (6) | Reinstall AGB breather tube (Ref. Airframe Maintenance Manual). |
| (1) | Remove accessory gearbox breather tube (Ref. Airframe Maintenance Manual). |
| (2) | Insert borescope probe through fan and core stators. (Ref. Fig. ). |
| (3) | Feed probe through VIGV until First-stage HP compressor blade is visible. |
| (4) | Inspect compressor blade. |
| (5) | Rotate engine slowly (using a 1/2 inch square drive wrench inserted through AGB breather outlet) and repeat until all 23 blades have been inspected. |
| (6) | Remove borescope. |
| (7) | Reinstall AGB breather tube (Ref. Airframe Maintenance Manual). |
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Airframe Maintenance Manual). |
| (2) | Remove six bolts (1) fastening cover (2) at blanked off LP bleed port. Remove cover (2) and gasket (3), discard gasket. |
| (3) | Install guide tube (PWC61803)with bolts (1) and feed borescope probe through guide tube into third-stage HP compressor vane area. |
| (4) | Position probe such that fourth-stage HP compressor blade can be viewed.
NOTE: It is possible to view blade leading edge only.
|
| (5) | Inspect fourth-stage compressor blade. |
| (6) | Rotate engine slowly (using a ½ inch square drive wrench inserted through accessory gearbox breather outlet) and repeat until all 39 blades have been inspected. |
| (7) | Remove borescope and guide tube. |
| (8) | Install cover (2) with new gasket (3) on LP bleed port, secure cover using six bolts (1). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (9) | Reinstall AGB breather tube (Ref. Airframe Maintenance Manual). |
| (1) | Remove P2.8 compressor bleed valves (Ref. 75-30-01). |
| (2) | Insert borescope through P2.8 compressor bleed valve port into impeller shroud area. |
| (3) | Inspect shroud from leading edge to rear case support flange 360 degrees. |
| (4) | Inspect impeller shroud for cracks.
|
| (6) | Remove borescope. |
| (7) | Install P2.8 compressor bleed valves (Ref. 75-30-01). |
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Gain access to igniter plugs (Ref. Aircraft Maintenance Manual). |
| (3) |
Disconnect ignition exciter input connector (Ref. Aircraft Maintenance Manual).
NOTE: It is necessary to remove only one igniter plug for borescope access.
|
| (4) | Loosen coupling nuts and disconnect ignition cable (1) from ignition exciter (2) and igniter plug (3). |
| (5) | Remove igniter plug (3) and gasket (4). |
| (6) | Examine igniter plug for damage (Ref. 74-10-01). |
| (7) | Feed borescope probe through igniter boss into combustion chamber liner. Manipulate
probe until fuel nozzle is visible.
NOTE: Guide tube (PWC43685) may be used to borescope fuel nozzles. Guide tube arrow must be pointing towards
the front-top of the engine at an angle of between 45 degrees and 90 degrees.
|
| (8) | Inspect fuel nozzle for evidence of:
|
| (12) | If any of above conditions are evident, inspect all downstream areas for damage. If no downstream damage is evident, engine may continue in service with a reduced borescope frequency of 50 operating hours. |
| (13) | Repeat procedure until all 24 fuel nozzles have been inspected.
NOTE: Fuel nozzles are line replacable (Ref. 73-10-04).
|
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Gain access to igniter plugs (Ref. Aircraft Maintenance Manual). |
| (3) |
Disconnect ignition exciter input connector (Ref. Aircraft Maintenance Manual).
NOTE: It is necessary to remove only one igniter plug for borescope access.
|
| (4) | Loosen coupling nuts and disconnect ignition cable (1, Fig. ) from ignition exciter (2) and igniter plug (3). |
| (5) | Remove igniter plug (3) and gasket (4). |
| (6) | Examine igniter plug for damage (Ref. 74-10-01). |
| (7) | Insert borescope (if available use a 5 mm borescope as this is more rigid and allows
operator to manoeuvre it inside the combustion liner) through the igniter plug opening.
Feed borescope through and inspect different areas of combustion liner.
NOTE: Guide tube (PWC43685) may be used to borescope the combustion liner. Guide tube arrow must be pointing
towards the front-top of the engine at an angle of between 45 degrees and 90 degrees.
|
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (7) | The following conditions are acceptable for continuing service with a repeat borescope
inspection of affected area(s) at no more than 1200 Flight Hours:
CAUTION: SUBSEQUENT BORESCOPE INSPECTIONS MUST BE DONE AT INTERVALS DEPENDING ON THE RATE
OF PROGRESSION AND LEVEL OF DETERIORATION SEEN.
|
| (13) | The following conditions are acceptable for continuing service with a repeat borescope
inspection of affected area(s) at no more than 400 Flight Hours:
|
| (16) | The following conditions require engine removal within 100 Flight Hours for the Combustion
Liner replacement:
|
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Gain access to igniter plugs (Ref. Aircraft Maintenance Manual). |
| (3) |
Disconnect ignition exciter input connector (Ref. Aircraft Maintenance Manual).
NOTE: It is necessary to remove only one igniter plug for borescope access.
|
| (4) | Loosen coupling nuts and disconnect ignition cable (1, Fig. ) from ignition exciter (2) and igniter plug (3). |
| (5) | Remove igniter plug (3) and gasket (4). |
| (6) | Examine igniter plug for damage (Ref. 74-10-01). |
| (7) | Install guide tube (PWC43685) in either igniter plug boss. The guide tube arrow must be pointing toward the front of the engine and down at an angle of between 30 degrees and 45 degrees. |
| (8) | Feed borescope through guide tube until first-stage HP turbine vane segment can be viewed. |
| (9) | To inspect as many vanes as possible, guide the borescope in front of the vane leading edges and push it in CW direction. |
| (10) | Inspect the leading edge then turn the borescope tip and go in between airfoils and inspect the convex and concave surfaces and adjacent turbine shroud. |
| (11) | Repeat the inspection procedure for the next airfoil and shroud. |
| (12) | Remove borescope and guide tube. |
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (6) | The following conditions are acceptable for continuing service with a repeat borescope
inspection of affected area(s) at no more than 200 Flight Hours:
CAUTION: SUBSEQUENT BORESCOPE INSPECTIONS MUST BE DONE AT INTERVALS DEPENDING ON THE RATE
OF PROGRESSION AND LEVEL OF DETERIORATION SEEN.
|
| (11) | The following conditions require engine removal within 100 Flight Hours for the First-stage
HP Turbine Vane replacement:
|
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (6) | The following conditions require engine removal within 100 Flight Hours for the First-stage
HP Turbine segment replacement:
|
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Gain access to igniter plugs (Ref. Aircraft Maintenance Manual). |
| (3) | Disconnect both ignition exciter input connectors (Ref. Aircraft Maintenance Manual). |
| (4) | Loosen coupling nuts and disconnect ignition cable (1, Fig. ) from ignition exciter (2) and igniter plug (3). |
| (5) | Remove igniter plug (3) and gasket (4). |
| (6) | Examine igniter plug for damage (Ref. 74-10-01). |
| (7) | Install guide tube (PWC43685) in either igniter plug boss. Guide tube arrow must be pointing forward at an angle of about 10 degrees to 20 degrees up. |
| (8) | Feed borescope through vane until first-stage HP turbine blade can be viewed. |
| (9) | Rotate engine slowly (using a ½ inch square drive wrench inserted through accessory gearbox breather outlet) and repeat until all 45 blades have been inspected. |
| (10) | If borescope inspection is conducted without P&WC assistance;
|
| (13) | Remove borescope and guide tube. |
| (1) | Feed borescope through the HP turbine vane until the first-stage HP turbine blade platform can be viewed. |
| (2) | Rotate the engine slowly (using a ½ inch square drive wrench inserted through accessory gearbox breather outlet) and repeat until the full circumference of the blade platform has been inspected. |
| (3) | Inspect the (Post-SB25104) L seal as follows:
|
| (1) | Inspect the Pre-SB25104 first-stage HP turbine blade airfoil, pressure side, at the TE close to the platform.
Record damage observed on worst affected airfoil.
|
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (8) | The following conditions are acceptable for continuing service with a repeat borescope
inspection of affected area(s) at no more than 200 Flight Hours or 200 Cycles, whichever
occurs first (Ref. Fig. ).
CAUTION: SUBSEQUENT BORESCOPE INSPECTIONS MUST BE DONE AT INTERVALS DEPENDING ON THE RATE
OF PROGRESSION AND LEVEL OF DETERIORATION SEEN.
|
| (15) | The following conditions are acceptable for continuing in service with a repeat borescope
inspection of affected area(s) at no more than 100 Flight Hours or 100 Cycles, whichever
occurs first. (Ref. Figs. and ):
|
| (20) | Post-SB25175 blades (Ref. Fig. ): the following damage is acceptable for continuing in service with a repeat borescope inspection of the affected area(s) at no more than 100 Hours or 100 Cycles, whichever occurs first, up to a maximum of 800 hours or cycles since the initial finding: airfoil pressure side radial crack less than 0.400 inch in length which originates near the bottom of the blade, less than 0.400 inch from the blade platform, and which propagates toward the blade tip. |
| (21) | The following conditions are acceptable for continuing in service with a repeat borescope
inspection of affected area(s) at no more than 50 Cycles or Hours, whichever occurs
first:
|
| (24) | The following conditions require engine removal within 50 Flight Hours for the First-stage
HP Turbine Blade replacement:
|
| (30) | The following conditions require immediate engine removal (Ref. Fig. ):
|
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Remove two bolts (1, Fig. ) securing borescope blanking plug (2) to LP turbine case. |
| (3) | Remove blanking plug (2), remove and discard seal ring (3). |
| (4) | Install guide tube (PWC62363). |
| (5) | Insert borescope through guide tube and position probe such that Second-stage HP turbine blade can be viewed. |
| (6) | Inspect Second-stage HP turbine blade. |
| (7) | Rotate engine slowly (using a ½ inch square drive wrench inserted through accessory gearbox breather outlet) and repeat until all 45 blades have been inspected. |
| (8) | Feed probe through Third-stage LP turbine vane until Third-stage LP turbine blade is visible. |
| (9) | Inspect Third-stage LP turbine blade (Ref. Table ). |
| (10) | Rotate LP shaft (fan) slowly and repeat until all 76 blades have been inspected. |
| (11) | Install new seal ring (3) on blanking plug (2). |
| (12) | Install blanking plug (2) in LP turbine case. |
| (13) | Apply a light coat of antiseize compound (PWC06-009) on bolts (1) and secure blanking plug (2). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (14) | Reinstall AGB breather tube (Ref. A.M.M.). |
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (4) | The following conditions are acceptable for continuing service with a repeat borescope
inspection of affected area(s) at not more than 1200 Flight Hours:
CAUTION: SUBSEQUENT BORESCOPE INSPECTIONS MUST BE DONE AT INTERVALS DEPENDING ON THE RATE
OF PROGRESSION AND LEVEL OF DETERIORATION SEEN.
|
| (8) | The following conditions require engine removal within 50 Flight Hours for the Second-stage
HP Turbine Blade replacement:
|
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (3) | The following conditions require engine removal in not more than 1200 Flight Hours
for the Second-stage HP Turbine segment replacement:
CAUTION: SUBSEQUENT BORESCOPE INSPECTIONS MUST BE DONE AT INTERVALS DEPENDING ON THE RATE
OF PROGRESSION AND LEVEL OF DETERIORATION SEEN.
|
| (1) | The following conditions are acceptable for continuing service with subsequent borescope
inspection at the regular interval:
|
| (4) | The following conditions are acceptable for continuing service with a repeat borescope
inspection of affected area(s) in not more than 1200 Flight Hours:
CAUTION: SUBSEQUENT BORESCOPE INSPECTIONS MUST BE DONE AT INTERVALS DEPENDING ON THE RATE
OF PROGRESSION AND LEVEL OF DETERIORATION SEEN.
|
| (8) | The following conditions require engine removal within 100 Flight Hours for the Second-stage
HP Turbine Vane Ring replacement:
|
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Remove two bolts (1, Fig. ) securing borescope blanking plug (2) to LP turbine case. |
| (3) | Remove blanking plug (2), remove and discard seal ring (3). |
| (4) | Install guide tube (PWC62363). |
| (5) | Insert borescope through guide tube. Adjust guide tube and borescope probe position such that Third-stage LP turbine vane can be viewed. Repeat until all LP vane airfoils are inspected. |
| (6) | Inspect Third-stage LP turbine vane. |
| (7) | Reposition probe and inspect as many vanes as possible. |
| (8) | Install new seal ring (3) on blanking plug (2). |
| (9) | Install blanking plug (2) in LP turbine case. |
| (10) | Apply a light coat of antiseize compound (PWC06-009) on bolts (1) and secure blanking plug (2). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (11) | Reinstall AGB breather tube (Ref. A.M.M.). |
| (1) | If necessary, remove accessory gearbox breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Remove two bolts (1, Fig. ) securing borescope blanking plug (2) to LP turbine case. |
| (3) | Remove blanking plug (2), remove and discard seal ring (3). |
| (4) | Insert borescope through access port, through Third-stage LP turbine vane until Third-stage LP turbine blade is visible. |
| (5) | Rotate LP shaft (fan) slowly and repeat until all 76 blades have been inspected. |
| (6) | Install new seal ring (3) on blanking plug (2). |
| (7) | Apply a light coat of antiseize compound (PWC06-009) on bolts (1) and secure blanking plug (2). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Reinstall AGB breather tube (Ref. A.M.M.). |
| (1) | The Low Utilization Inspection (LUI) must be performed as per the following instructions:
|
| • | two for P2.5 compressor bleed valves. |
| • | two for P2.8 compressor bleed valves. |
| • | two for cabin bleed air tubes. |
| • | one for P2.8 anti-ice solenoid valve. |
| • | two for airframe supplied rudder bias system. |
| • | one for P2.8 bearing air seal pressurization. |
| Tool No. | Name | Application |
|---|---|---|
| PWC30128-03 | Puller |
|
| PWC32396-100 | Jackscrew |
|
| PWC37807 | Pump |
|
| PWC40263 | Adapter |
|
| PWC40781 | Adapter, Dyno-Torque Wrench |
|
| PWC41050 | Wrench |
|
| PWC43248 | Pad |
|
| PWC43250 | Protector |
|
| PWC43260 | Socket |
|
| PWC43261 | Socket |
|
| PWC43262 | Adapter |
|
| PWC43264 | Puller |
|
| PWC43515-11 | Bar |
|
| PWC60668 | Crimper |
|
| PWC60758 | Sleeve Spacer |
|
| PWC60773 | Spreader |
|
| PWC60903 | Slave Washer |
|
| PWC60926 | Crimper | Obsolete - replaced by PWC62073 |
| PWC61013 | Fan Guide |
|
| PWC61404 | Adapter |
|
| PWC61783 | Holding Fixture |
|
| PWC61793 | Lifting Fixture, Fan |
|
| PWC61996 | Retaining Ring |
|
| PWC62019 | Retaining Ring |
|
| PWC62073 | Crimper | Alternate to PWC60926 |
| PWC62180 | Locator, Key Washer |
|
| PWC63068 | Heat Shield |
|
| PWC71392 | Adapter |
|
| PWC89837 | Hydraulic Cylinder |
|
| PWC90000 | Heat Gun |
| (1) | Put an index mark on the inlet cone and fan blade in line with the V-mark on the inlet cone using an approved marker (PWC05-018). |
| (2) | Unstake nose cone keywasher (2) using socket (PWC43260). |
| (3) | Remove compressor inlet cone bolt (1) using socket (PWC43260), remove and discard inlet cone keywasher (2). |
| (4) | Remove nose cone drive key (3) . |
| (5) | Pre-SB25058 Engine Only:
|
| (7) |
Post-SB25058 Engine Only:
|
| (1) | Turn the fan until the V-mark on the blade retaining ring is at top center. Put a mark on the number one fan blade in line with the V-mark, using an approved marker (PWC05-018). |
| (2) | Install inlet cone (4) over low compressor tie-rod (6) with V-mark at top. |
| (3) | Push the inlet cone all the way on. Turn inlet cone until slot in cone aligns with the slots in the tie rod end. |
| (4) | Install puller (PWC30128-03) into end of tie rod (6) and pull tie rod forward until fully engaged. |
| (5) | Install drive key (3) in inlet cone (4). Turn inlet cone if necessary until drive key can be inserted. |
| (6) | Install keywasher (2) and compressor inlet cone bolt (1) . |
| (7) | Centralize keywasher using (PWC62180). Loctite (PWC08-014) may be applied sparingly to make sure the keywasher tab (2) remains braced against the drive key slot in a counterclockwise position during the torquing of the nose cone bolt (1). |
| (8) | Torque bolt (1) using socket (PWC43260) (Fits and Clearances, REF. NO. 1701). |
| (9) | Stake nose cone keywasher (2) into two opposing slots of inlet cone bolt with crimper (PWC60926) or (PWC62073). |
| (10) | Check for fit and clearance of the keywasher. Fits and Clearances, REF. NO. 1420 is 0.095 inch Axial in two places (Ref. Fig View A). |
| (1) | Apply a light coat of anti-seize compound (PWC06-004) to the compressor inlet cone on the surface shown (Ref. Fig. ). |
| (2) | Remove the retaining ring (PWC61996). |
| (3) | Install the compressor inlet (nose) cone and rotate until the slot in the nose cone and the slot in the tie rod are aligned and the V-mark on the nose cone is aligned with the top center of the fan assembly. Put a mark on the number one fan blade in line with the V-mark, using an approved marker (PWC05-018). |
| (4) | Install inlet cone (1) over low compressor tie-rod (5) with V-mark at top. |
| (5) | Push the inlet cone all the way on. Turn inlet cone until slot in cone align with the slots in the tie rod end. |
| (6) | Install puller (PWC30128-03) into end of tie rod (5) and pull tie rod forward until fully engaged. |
| (7) | Install drive key (4) in inlet cone (1). Turn inlet cone if necessary until drive key can be inserted. |
| (8) | Loctite (PWC08-014) may be applied sparingly to make sure the keywasher (3) tab remains braced against the drive key (4) slot in a counterclockwise position during the torquing of the nose cone bolt. |
| (9) | Install keywasher (3) and compressor inlet cone bolt (1). Torque bolt using socket (PWC43260) (Ref. 72-30-01, Fits and Clearances, Table 402, REF. NO. 1701). |
| (10) | Stake nose cone keywasher (3) into two opposing slots of inlet cone bolt with crimper (PWC62073) or (PWC60926). |
| (11) | Check for fit and clearance for the keywasher. Fits and Clearances, REF. NO. 1420 is 0.095 inch Axial (2 Places). |
| (1) | Push tie-rod (6) rearward until lugs disengage from tie-rod retaining nut (7) using puller (PWC30128-03). |
| (2) | Remove tie-rod retaining nut (7). |
| (3) | Remove tie-rod (6) using puller (PWC30128-03). Remove and discard preformed packing (8) . |
| (1) | Find and mark the master slot of low compressor shaft,
tie rod retaining nut (7)
and master lug of
low compressor tie-rod (6)
using an approved marker (PWC05-018).
NOTE: Master slot and lug are wider than the others.
|
| (2) | Lubricate and install one new preformed packings (8) onto low compressor tie-rod (6) using (PWC03-001). Align master lug of tie-rod with master slot of low compressor shaft and insert tie rod. |
| (3) | Install tie rod retaining nut (7) onto low compressor shaft until contact is made with lugs of tie-rod (6). |
| (4) | Unscrew tie rod retaining nut (7) until the master slot aligns with master lug of low compressor tie rod (6). Pull tie rod forward until lugs of tie-rod engage slots of retaining nut. |
| (1) | Remove the compressor inlet cone (Ref. Para. 5A, Compressor Inlet Cone). |
| (2) | Install blade retainer (PWC61996). |
| (3) | Mark the fan blades with an approved marker (PWC05-018) with reference to the 'V' mark on the hub. The No. 1 blade is the closest counterclockwise of the 'V' reference. Mark all 22 blades in counterclockwise direction (leading edge view). |
| (4) | Record on the Fan Blade Distribution Chart, the moment weight and serial number of
all 22 blades in the existing assembly, including the blades to be replaced.
NOTE: The blade moment weight is marked on the front of the blade platform.
|
| (5) | Send the blade information recorded in step including the Serial No. and Moment Weight of the new blades to be installed to PWC Help Desk. Also send the fan blade inspection results of all blades. |
| (6) | PWC Help Desk will provide the new optimum circumferential positions of the fan blades. |
| (7) | Based on the printout results, mark all 22 blades including the replacement blade/s of the fan assembly in counterclockwise direction (leading edge view) with an approved marker (PWC05-018) starting with No. 1 blade. The nearest slot counterclockwise (leading edge view) from the 'V' mark is the slot position of No. 1 blade. The remaining blades are numbered in counterclockwise direction (leading edge view) up to No. 22. |
| (8) | Remove the blade retainer (PWC61996) from the fan assembly and replace with a slotted blade retainer (PWC62019) for individual removal/installation of the blade. |
| (9) | Take note of the alignment mark 'V' on the hub. Remove the damaged blades and reposition the blades including the replacement blades in accordance with printout results of redistribution from PWC Help Desk. Use the slotted blade retainer (PWC62019) to individually remove/install the blade. |
| (10) | Remove the retainer and install compressor inlet cone (Ref. Para. 5, Compressor Inlet Cone - Installation - Post-SB25058). |
| (11) | Restore engine to standard operating condition. Ground run the engine and check for vibration (Ref. 71-00-00, Adjustment and Test). |
| (1) | Remove retaining ring (9) and keywasher (10) . |
| (2) | Unstake cupwasher (12) using unstaking tool (PWC60773). |
| (3) | Install adapter (14) (PWC43262) into end of low compressor shaft (Ref. Sht. 2). |
| (4) | Install socket (15) (PWC43261) over adapter (14) and onto fan retaining nut (11). |
| (5) | Insert drive bar (16) (PWC43515-11) into end of adapter. |
| (6) | Install wrench (17) (PWC41050) over drive bar and locate on drive spline of socket. |
| (7) | Install adapter (18) (PWC40781) on rear of drive bar and locating holes on rear face of wrench. Attach using two socket head screws (19) . |
| (8) | Loosen fan retaining nut (11) . |
| (9) | Remove previously installed special tooling, fan retaining nut (11) and cupwasher (12). Discard cupwasher. |
| (10) | Attached lifting fixture (PWC60449) to a suitable hoist and install on fan assembly (5). |
| (11) | Insert pad (20) (PWC43248) into end of low compressor shaft. |
| (12) | Install puller (21) (PWC43264) on fan assembly (5) . |
| (13) | Screw adapter (22) (PWC71392) on cylinder (23) (PWC89837). |
| (14) | Install cylinder assembly on puller (21). Make sure that locking features engage. |
| (15) | Connect cylinder hose to hydraulic pump (24) (PWC37807). |
| (16) | Slowly operate hydraulic pump and remove fan assembly (5) from low compressor shaft. |
| (17) | Remove previously installed puller and related tooling. |
| (18) | Place fan assembly in a suitable container and remove lifting fixture. |
| (19) | Remove adjusting spacer (13) from low compressor shaft. Measure and record spacer thickness as Dim. S. |
| (1) |
Lift
fan assembly (12)
using method 1 or method 2 as follows:
|
| (11) | Install fan case protector (17) onto the inner diameter of the fan case at the 12 o'clock position. |
| (12) | Attach fan lifter to a suitable overhead crane. |
| (13) | Lift fan assembly until the fan hub is at the same height as, and aligned with, low compressor shaft. |
| (14) |
Heat fan bore using method 1 or method 2 as follows:
|
| (24) | Install fan spacer (10) onto LP shaft (9) . Remove heating tooling and install fan assembly immediately. |
| (25) | Remove fan case protector (PWC62593) |
| (26) | Install drift (20) (PWC60399), adapter (21) (PWC40263), hydraulic cylinder (19) (PWC89837), hydraulic pump (18) (PWC37807) and cooling ring (PWC64330) or air cooling tool (PWC89835). |
| (27) | Apply 700 - 1000 psi to seat LP shaft components. |
| (28) | Connect air supply to cooling ring or air cooling tool. |
| (29) | Maintain pressure until assembly reaches room temperature. |
| (30) | Remove tooling. |
| (1) | Pre-SB25335: If the replacement fan retaining nut (11) is new proceed to step . If not, apply one coat of anti-galling compound (PWC06-032) to the threads and thrust face of the retaining nut using a brush or swab before installation. Anti-galling compound must be completely removed and then re-applied to nut thread and thrust face area following each complete torque cycle (Ref. Fits and Clearances, REF. NO. 1702). |
| (2) | Post-SB25335: Apply anti-seize compound (PWC06-004) to the nut thread and thrust face and to shaft thread. Remove excessive compound wherever possible (Ref. Fits and Clearances, REF. NO. 1702). |
| (3) | Install slave washer (PWC60903) on low compressor shaft. |
| (4) | Install adapter (3) (PWC43262) into end of low compressor shaft. |
| (5) | Install socket (4) (PWC43261) over adapter (3) and onto fan retaining nut (11). |
| (6) | Insert drive bar (PWC43515-11) into end of adapter. |
| (7) | Install wrench (5) (PWC41050) over drive bar and locate on drive spline of socket. |
| (8) | Install adapter (6) (PWC40781) on rear of drive bar and rear face of wrench. Attach using two socket head screws (19). |
| (9) | Torque fan retaining nut (11) (Ref. Fits and Clearances, REF. NO. 1702). |
| (10) | Remove previously installed special tooling. |
| (11) | Measure the fan blade leading edge (LE) tip clearances (Ref. Para. ). |
| (12) | Install keywasher (10) and retaining ring (11). |
| (13) | Stake cupwasher (12), at four locations, using staking tool (9) (PWC60668). |
| (14) | Install tie-rod (Ref. Para. ). |
| (15) | Install compressor inlet cone (Ref. Para. ). |
| (16) | Refer to Chapter 71-00-00, for checks following installation of fan assembly. |
| (1) | Load low compressor shaft rearwards. |
| (2) | With each blade loaded to the rear and outward, check leading edge LE tip clearance at a common point on the fan case. Find and mark longest fan blade using an approved marker(PWC05-018). |
| (3) | With longest blade loaded to the rear and outward, measure and record leading edge tip clearances at four locations around the fan case (Ref. Fig. ). Calculate the average clearance and record it as Dim. b. Make sure clearances are within limits specified (Fits and Clearances, REF. NO. 1256). |
| (4) | If fan blade tip clearance is within limits measure the gap between the rear fan blade
retaining ring and the compressor inlet vane assembly. There must be a minimum gap
of 0.070 inch (1.78 mm) (Ref. View B).
|
| (7) | Adjustment of fan tip clearance, if required, is achieved by varying the thickness
of the fan spacer as follows:
|
| (10) | Repeat Para. and Para. , step to . |
| (11) | If fan clearance is now within limits go to Para. , step .
|
| (1) | Calculate and record the thickness of the fan spacer necessary to bring the fan blade
tip clearance within limits using the following formula. a = S ± (C × 0.01) where:
|
| (2) | Adjust fan tip clearance by grinding a new or existing adjusting spacer to Dim. a ± 0.0005 inch (0.013 mm) (Ref. Fig. ). |
| (3) | Faces of spacer must be parallel within 0.0002 inch (0.005 mm), flat within 0.0002 inch (0.005 mm) and have a surface finish of 63 micro-inches or better. |
| (4) | Break sharp edges 0.003 to 0.015 inch (0.08-0.38 mm). |
| (5) | Spray wash spacer (14) using petroleum solvent (PWC11-027). |
| (6) | Check for residual magnetism using a standard field gauge. Negate any residual magnetism. |
| (1) | Remove EEC (Ref. 73-20-02). |
| (2) | Remove nut (20) , washer (19) , bolt (18) and support tube (17) . |
| (3) | Remove nuts (4) , shipping bracket and EDU rear support bracket (16) (Ref. View B). |
| (4) | At location M, two places, remove nuts (4), washers (3) and fire detector brackets (15) . |
| (5) | At location R, remove nut (4), washer (3), bolt (14) and tube support bracket (13) . |
| (6) | At location N, remove nut (4) and tube support bracket (13). |
| (7) | Remove nut (4), washer (3), bolt (12) and support (11) (Ref. Section S-S). |
| (8) | At location T, remove nuts (4), washers (3), bolts (10) and engine lift bracket (9) . |
| (9) | At location L, two places, remove nuts (4) and washers (3). |
| (10) | At location P, remove nut (8) , washers (7) and bolt (6) . |
| (11) | At location J, four places, remove nuts (4), washers (3) and bolts (5) . |
| (12) | At location K, three places, remove nuts (4), washers (3) and bolts (2) . |
| (13) | Install three jacking screws (PWC32396-100) into jacking inserts in fan case Flange B. |
| (14) | Support the weight of the fan case and tighten the jacking screws in a star pattern until the fan case releases from the intermediate case. |
| (15) | Remove fan case (1) . |
| (1) | Apply a thin coat of grease (PWC09-003) to the mating flange of the fan case (1) . Align bolt holes and install fan case assembly. |
| (2) | Location K.
|
| (4) | Location J.
|
| (6) | Location P.
|
| (8) | Location L.
|
| (10) | Location T.
|
| (12) | Location S.
|
| (14) | Location N.
|
| (16) | Location R.
|
| (18) | Location M.
|
| (20) | Install EDU rear support bracket (16) and shipping bracket with 2 nuts (4). Install shipping bracket facing rearward installed on top or bracket facing forward. Torque 62 to 72 lb. in. (7.0 to 8.1 Nm) dry. |
| (21) | Install support tube (17) with bolt (18) , washer (19) and nut (20) . Torque 36 to 40 lb. in. (4.1 to 4.5 Nm). Torque nut and bolt at other end of support tube 62 to 72 lb. in. (7.0 to 8.1 Nm) dry. |
| (22) | Install EEC (Ref. 73-20-02). |
| (1) | Remove bolts (1) , keywashers (2) from compressor inlet vane. |
| (2) | Install fixture (PWC61783) to the compressor inlet vane and remove the vane assembly from the intermediate case by turning the assembly using the fixture. |
| (3) | Remove bolts (4) , washers (5) and fan exit vane ring (6) from intermediate case (7) . |
| (1) | Align 3 lugs on fan exit vane ring (6) into 3 slots of intermediate case (7) , make sure drain hole is at BDC. |
| (2) | Attach vane ring (6) to intermediate case (7) with 6 bolts (1) and 6 washers (5) . Torque bolts 36 to 40 lb. in. (4.1 to 4.5 Nm). |
| (3) |
Apply a thin coat of silicone grease (PWC09-003) on mating surfaces for ease of installation. Install fixture (PWC61783) by rotating into position aligning bolt holes.
NOTE: Make sure fixture (PWC61783) is locked and secured correctly into position (pins fit rotation holes).
|
| (4) | Secure vane ring (6) to intermediate case (7) with 6 bolts (4) and 6 keywashers (2) . Torque bolts 65 to 85 lb. in. (7.4 to 9.7 Nm) and lock tabwashers. |
| (1) | Disconnect N1 speed probe wiring harness from N1/T4.5 terminal box (Ref. 77-20-01). |
| (2) | Disconnect No. 4 bearing pressure and scavenge oil tubes from exhaust case (Ref. 79-20-03 and 79-20-04). |
| (3) | Disconnect emergency fuel shut-off cable (Ref. 73-10-05). |
| (4) | Disconnect and remove T4.5 “IN” wiring harness connections from N1/T4.5 terminal box (Ref. 77-20-01). |
| (5) | Remove exhaust case(Ref. 72-50-03). |
| (6) | Remove LP turbine module (Ref. 72-50-02). |
| (7) | Install protector (PWC43250) on rear end of LP shaft. |
| (8) | Remove compressor inlet cone (Ref. Para. ). |
| (9) | Remove low compressor tie rod (Ref. Para. ). |
| (10) | Remove fan balancing assembly (Ref. Para. ). |
| (11) | Install sleeve spacer (3) (PWC60758) and secure with fan retaining nut (2) , handtight. |
| (12) | Remove 12 nuts (6) and bolts (4 ) from No. 1 bearing housing (5) . |
| (13) | Install three jacking screws (PWC32396-100) in the No. 1 bearing housing jacking inserts. |
| (14) | Carefully withdraw LP shaft and No. 1 bearing housing (1) together by evenly turning jacking screws and pulling LP shaft and housing assembly from engine. |
| (15) | Secure two halves of No. 1 bearing housing together using two slave nuts and bolts. |
| (16) | Discard preformed packing (8) . |
| (17) | Remove transfer tube (11) (Ref. Sht. 2) and discard preformed packings (10) . |
| (1) | Install protector (PWC43250) on the rear of LP shaft (1) . |
| (2) | Lubricate and install new preformed packing (8) on No. 1 bearing housing (5) . |
| (3) | Lubricate and install two new preformed packings (10) on oil transfer tube (11) . |
| (4) | Push transfer tube (11) into No. 1 bearing oil nozzle assembly (12) . |
| (5) | Remove slave nuts and bolts from No. 1 bearing housing. |
| (6) | Make sure oil transfer tube (11) is aligned with No. 1 bearing oil nozzle (12) and oil transfer tube housing (9) and insert LP shaft assembly and bearing housing assembly into engine. |
| (7) | Secure No. 1 bearing housing assembly (5) to No. 1 bearing support with 12 bolts (4 ) and nuts (6) . Torque 27 to 30 lb.in. (3.0-3.4 Nm.) using a star tightening pattern. |
| (8) | Remove fan retaining nut (2) ) and sleeve spacer (3). |
| (9) | Install fan balancing assembly (Ref. Para. ). |
| (10) | Install compressor inlet cone (Ref. Para. ). |
| (11) | Install low compressor tie rod (Ref. Para. ). |
| (12) | Remove protector (PWC43250) from rear end of LP shaft. |
| (13) | Install LP turbine module (Ref. 72-50-02). |
| (14) | Install exhaust case (Ref. 72-50-03). |
| (1) | Check for foreign object damage and erosion. |
| (2) | Check for evidence of cracks. No cracks permitted. |
| (3) | Check for dents. A maximum of two dents permitted, provided depth is not greater than 0.100 inch and span is not greater than 1.0 inch. Dents directly adjoining each other are not acceptable. |
| (4) | Nicks on surface is serviceable if it is in the limits that follows:
|
| (5) | Local erosion, minor surface pitting and corrosion 0.010 in. (0.25 mm) deep maximum is serviceable. |
| (6) | Post-SB25058: Fretting on the fan blade retaining face (Face A) is permitted up to 0.015 in. (0.38 mm) deep maximum if there is no fretting on the blade platform mating face (Face B). |
| (1) | A fan with blade damage beyond the blend repair limits (Ref. Table ) must be removed from service and sent to an approved overhaul facility for repair. If an aircraft must be flown to a facility equipped for fan removal, record the extent of the blade damage and submit this information to Pratt & Whitney Canada Inc. A review of the information may permit P&WC to recommend limited engine operation for purposes of obtaining flight permission from the operator's regulatory authority. |
| (2) | Inspect the blade LE for erosion. Blend the LE to restore original radius as shown (Ref. Fig. , Detail K), if the LE flat exceeds 0.020 inch. |
| (3) | Inspect LE for bends or deformation. Bends or deformation is acceptable providing the displacement of material does not exceed 0.020 inch perpendicular to the LE span and the length of the bend is less than 0.060 inch along the LE span and the bend is smooth and continuous (Ref. Fig. , View B). |
| (4) | Inspect blade for tears (Ref. Fig. ) and cracks. Tears and cracks are not acceptable. |
| (5) | Inspect blade for nicks (Ref. Fig. ) and dents (Ref. Fig. ). For disposition refer to (Ref. Fig. and Table ). |
| (6) | Blade tip inspection (area I). Perform this inspection if the blade is removed from the engine. Blend surface damage in form of burrs, rubs or wear to a maximum depth of 0.005 inch. |
| (1) | Visually check fan case without the aid of magnification. Magnification up to 4X may be used as an aid to evaluate observed damage. |
| (2) | Stainless Steel Case:
|
| (7) | Visually check abradable lining (Area f) for foreign inclusions, holes, or cracks (Ref. Table ). |
| (8) | Perforated Liner (Area h) for (Ref. Table ):
NOTE: The perforated area of the liner segment is aluminum alloy (AMS 4348)
|
| (11) | Dimensionally check abradable lining for wear (Fits and Clearances, REF. NO. 1256). |
| (1) | Vanes:
|
| (6) | Inner and Outer Shrouds:
|
| (9) | All other surfaces:
|
| (1) | Refer to definitions of damage and acceptable limits as specified in Table . |
| (2) | Visual checks:
|
| Item No. | Name |
|---|---|
| PWC05-064 | Solution, Anodize |
| PWC05-069 | Tape, Pressure Sensitive Adhesive |
| PWC05-161 | Solution, Touch-Up Chrome pickle |
| PWC05-184 | Compound, Potting |
| PWC05-197 | Acid, Chromic |
| PWC06-004 | Compound, Antiseize |
| PWC07-011 | Varnish, Air-Dry |
| PWC07-014 | Varnish, Phenolic Resin |
| PWC08-016 | Paste, Adhesive |
| PWC08-016A | Paste, Adhesive, Epoxy |
| PWC08-018A | Paste, Adhesive, Epoxy |
| PWC09-017 | Adhesive/Sealant, Silicone Rubber |
| PWC11-005+ | Envirosolv 655 |
| PWC11-012 | Acetone |
| PWC11-014 | Alcohol, Isopropyl |
| PWC11-019 | Solution, Chromate Conversion |
| PWC11-023+ | Ardrox Leeder 1064K |
| PWC11-025+ | Desoclean 45 |
| Tool No. | Name |
|---|---|
| PWC62019 | Ring, Retaining |
| PWC66581 | Fan Wedge |
| (1) | Fan blades may be repaired if damage is not in excess of limits (Ref. Inspection). |
| (2) | Mask surfaces adjoining damaged areas using pressure sensitive tape (PWC05-069). |
| (3) | Blend out in a lengthwise direction nicks, scratches, pits and sharp edges using small hand files and stones. Finish blend using fine stones to ensure surface finish is restored to that of surrounding surface. Maintain a smooth transition to adjoining areas. |
| (4) | Blade LE and TE radii shall be restored by blending convex surface, and minimizing blending on the concave surface. |
| (5) | Repaired area depth shall be 1/3 deeper than the depth of the damage to ensure complete damage removal. |
| (6) | Where possible local repair of airfoil surface (area H) shall extend over an area five (5) times the depth of the damage. |
| (7) | The blade airfoil, LE and TE shall be repaired sufficiently to remove damage. Material removal shall be minimized to reduce the effect on fan balancing and engine performance. |
| (8) | Remove pressure sensitive tape and clean off any residual adhesive using alcohol (PWC11-014). |
| (1) | Remove nose cone and install fan blade retaining ring (PWC62019). Turn the retaining ring and make sure that the gap to remove the blade is at the 12 o' clock position. |
| (2) | Install fan wedges (PWC66581) to prevent fan rotation during application of lubricant. |
| (3) | Remove fan blade from TDC position. |
| (4) | Apply antiseize compound (PWC06-004) on contact surfaces of fan blade roots. |
| (5) | Install the fan blade and adjust retaining ring (PWC62019) to the next blade. Remove fan wedges (PWC66581) and turn the LP rotor balancing assembly to move the next blade to TDC position. |
| (6) | Repeat Steps thru until all the blade are coated. |
| (7) | Install fan nose cone (Ref. 72-30-01, LP COMPRESSOR - REMOVAL/INSTALLATION). |
| (8) | Do a engine ground run check (Ref. 71-00-00, ADJUSTMENT/TEST). |
| (1) | Clean affected area f (Ref. Inspection) of contaminants or debris by scraping or sanding. Do not flush affected area with
solvents as this tends to draw oil/grease into repair area.
NOTE: Abradable material is pale blue in color. Contaminant (black residue) removal is
obvious when original color is obtained.
|
| (2) | Blow off affected area with clean, oil free compressed air or nitrogen. |
| (3) | Mix EC-3524 B/A (PWC05-184) per following parts by weight (pbw) requirements. Weigh each material to the nearest
gram of the specified amount. Mix enough to fill the repair area(s).
|
| (4) | Mix in a plastic or metal container using a plastic spatula, and to a uniform pale blue color. |
| (5) | Spread potting compound into repair area using a straight edge spatula. Make sure
material completely bonds to the repair surface by working the material into the
repair area until it darkens and moistens the existing surrounding material.
NOTE: Adequate bond will not occur if the potting compound is not worked into the repair
area until it darkens and moistens the existing cured material surrounding the repaired
area.
|
| (6) | Make sure potting material is flush with adjacent surfaces, to maintain gas path profile. |
| (7) | Allow the repaired material to cure at room temperature 21°C (70°F) for 16 hours or cure at 66°C (150°F) for 2 hours. |
| (8) | Sand finish excess material using 400 grit to return to original gas path profile. |
| (1) | Drill several holes 1/8 inch in diameter, 1 inch apart, through delaminated section. The holes must be not less than 1/2 inch from the leading edge of the abradable lining. |
| (2) | Inject silicone rubber compound (PWC09-017) into holes. |
| (3) | Apply light pressure to abradable to evenly spread compound under abradable. |
| (4) | Remove any excess material from surface of abradable. |
| (5) | Make sure holes are completely filled with silicone rubber compound. |
| (6) | Cure to manufacturer's instructions. |
| (1) | Remove delaminated piece of abradable material. |
| (2) | Repair abradable in accordance with repair procedure "Repair of Cracks or Holes in Abradable Lining" (using potting compound PWC05-184). |
| (1) | Flush clean affected area with isopropyl alcohol (PWC11-014) or acetone (PWC11-012) or ardrox leeder 1064K (PWC11-023+) or desoclean 45 (PWC11-025+) or envirosolv 655 (PWC11-005+). Air dry for 30 minutes minimum at room temperature. |
| (2) |
Mix EA934 NA (PWC08-016) per the following parts by weight (pbw) requirements. Weigh each material to the
nearest gram of the specified amount. Mix enough to fill the repair area(s). Mix
in a plastic container or metal container using a plastic spatula.
|
| (3) | Fill a syringe with a suitable quantity of EA934NA mixture and inject repair area. |
| (4) | Inject the damaged area and the adjacent cells surrounding the damaged area. |
| (5) | Wipe excess mixture from perforated liner surface. |
| (6) | Allow 5-7 days at room temperature for full cure or 2-3 hours at 66°C (150°F) temperature using hot air gun. |
| (7) | Sand finish repaired area to ensure smooth and burr free surface using 400 grit sand paper. |
| (8) | Touch up any sanded perforate in Area h (Ref. Inspection) using anodize solution (PWC05-064). |
| (1) | Seal the oil passages, air holes and area around corroded surface. |
| (2) | Clean the corroded area. Refer inspection for acceptable limits. |
| (3) | Apply chromate solution (PWC11-019) or chrome pickle solution (PWC05-161) to the bare metal surfaces of intermediate case (Ref. 70-00-00, STANDARD PRACTICES - REPAIR). |
| (4) | Restore protective coating on painted surfaces (Ref. 70-00-00, STANDARD PRACTICES - REPAIR). |
| (1) | Place a suitable blank or debris collector to prevent ingress of debris into the compressor or any other openings. |
| (2) | Manual blend repair the corrosion or impact damage and treat reworked surface (Ref. 70-00-00, STANDARD PRACTICES - REPAIR). Refer inspection for acceptable limits. |
| (3) | Apply epoxy (PWC08-016A) or (PWC08-018A) to fill the impact damaged, eroded or corroded area. (Ref. 70-00-00, STANDARD PRACTICES - REPAIR). |
| (4) | Remove blank on completion and vacuum or wipe area to remove any remaining debris. |
| (1) | Visually check for:
|
| (4) | Check torque of duct retaining bolts. Torque as necessary 32 to 36 lb.in. (3.6-4.0 Nm). If torque value is not achieved, replace Helicoil insert with oversize inserts as necessary (Ref. 70-00-00, STANDARD PRACTICES). |
| (1) | Visually check:
CAUTION: MAKE SURE DRILL DOES NOT DAMAGE DIFFUSER CASE.
|
| (5) | Shield assembly with damage in excess of above limits must be replaced. |
| (1) | Visually check for cracks. No cracks permitted. |
| Tool No. | Name |
|---|---|
| PWC32396-100 | Jacking Screws |
| PWC43022 | Sling, Engine in stand |
| PWC60288 | Puller |
| PWC61012 | Cooling Ring Set |
| PWC61148 | Alignment Pin (3 Req'd) |
| PWC61723 | Base |
| PWC64241-3 | Pin |
| (1) | Remove the bolt (13) and nut (14) fastening the tube bracket to the No. 4 scavenge oil tube. |
| (2) | Remove the bolts (7) fastening the fuel tube assembly (6) to the bypass duct. |
| (3) | Remove the bolt (11) and self-locking nut (4) fastening the loop clamp (5) to the angle bracket (10). |
| (4) | Remove and discard the lockwire from the coupling nuts (3). |
| (5) | Loosen the coupling nuts (3) and remove the primary fuel tube assembly (6) . |
| (6) | Remove the transfer tubes (2) . Remove and discard the preformed packings (1) . |
| (7) | Remove and discard the preformed packings (8) and (9) . |
| (8) | Remove the loop clamp (5) from the primary fuel tube assembly (6). |
| (1) | Pre-SB25039: Remove lockwire (PWC05-089) from drain tube (2, Fig. ) and combustor case lug. |
| (2) | Post-SB25039: Remove lockwire (PWC05-089) from drain tube (2, Fig. ) and lower bypass duct bracket (5) . |
| (3) | Remove drain tube (2) , (Fig. ) and gasket (1) from bottom of combustor outer case. Discard gasket (1). |
| (4) | Remove bypass duct support ring(13) ,(Fig. ). |
| (5) | Attach sling (4) (PWC43022) to combustor assembly (6) and attach sling to suitable hoist. Adjust hoist to support the weight of the combustion chamber assembly. |
| (6) | Remove 11 nuts (7) , 11 bolts (9) and upper bracket assembly (2) (Fig. , Ref. Location B). |
| (7) | Remove nine nuts (7), nine bolts (9) and lower bracket assembly (5) (Fig. , Ref. Location B). |
| (8) | Remove remaining 80 nuts (7), bolts (8) , (10) and four blanking plates (3) . |
| (9) | Install four jacking screws (PWC32396-100) in holes previously covered by blanking plates (3). |
| (10) | Slowly separate combustor assembly from gas generator case by simultaneously turning jacking screws and gently tapping on the front face of the turbine disk air nozzle (11) . |
| (11) | Remove and discard seal ring (12) . |
| (12) | Put combustor on bench and remove sling. |
| (13) | Remove jacking screws from combustor case. |
| (1) | Remove two igniters (2) , (Fig. ) and gaskets (3) . |
| (2) | Remove bolts (8) , (Fig. ) and the tube retaining plates (9) . |
| (3) | Remove 24 fuel manifold tube assemblies (6) from fuel nozzles and fuel inlet nozzle with puller (PWC60288) . |
| (4) | Remove bolts (10) and three fuel nozzles (2) , 120 degrees apart, and install three locators (6, Fig. ) (PWC61148). |
| (5) | Secure locaters (6) with screws (7) fingertight. |
| (6) | Remove bolt (10, Fig. ) and the fuel inlet nozzle (1). |
| (7) | Remove the remaining bolts (10) and the fuel nozzles (2). Completely remove one nozzle before proceeding to the next. |
| (8) | Remove and discard the metal gaskets (11) from 23 fuel nozzles (2) and one fuel inlet nozzle (1) . |
| (9) | Remove and discard the preformed packings (3) from the fuel nozzles. |
| (10) | Remove the inner fuel manifold tubes (5) from the outer fuel manifold tubes (7) . Remove and discard the preformed packings (4) . |
| (11) | Place closures over all openings of fuel nozzles and fuel inlet nozzle and place in individual containers. |
| (12) | Remove locaters and remove combustion chamber liner. |
| (1) | Install alignment pins (PWC64241-3), one in offset hole of inner liners (3) . |
| (2) | Install outer outer liner (1) over inner liner (3) aligning pin and offset hole of outer liner. |
| (3) | Remove alignment pins. |
| (4) | Lubricate bolt (2) with engine oil (PWC03-001), and install in smaller offset hole. |
| (5) | Lubricate remaining bolts with engine oil (PWC03-001) and install around inner and outer flange. |
| (6) | Starting with bolt at offset hole, tighten bolts 36 to 40 lb.in (4.0-4.6 Nm) in a star pattern. |
| (1) | Install combustor outer case (4) , (Fig. ) on base (5) (PWC61723). |
| (2) | Install liner (1) in case (4). |
| (3) | Install three alignment pins (6) (PWC61148), each 120 degrees apart, in case (4) to align liner and case. Fasten pins (6) with bolts (7) fingertight. |
| (4) | Install gaskets (3) on igniters (2) and install in case (4). Make sure igniters can be seated by hand, then torque to 350 lb.in. (39.5 Nm). |
| (1) | Lubricate preformed packings (4) with engine oil (PWC03-001) and install on inner fuel manifold tubes (5) . |
| (2) | Introduce inner manifold tubes (5), with side having an extra shoulder, into outer manifold tubes (7) , through end with flats. Thread inner manifold tubes (5) into outer manifold tubes (7) until threaded shoulder on inner tube is trapped between shoulders of outer tube. |
| (3) | Lubricate preformed packings (3) with engine oil (PWC03-001) and install on inlet nozzle (1) and fuel nozzles (2) . |
| (4) | Insert 24 fuel manifold tube assemblies, (6) onto 23 fuel nozzles (2) and one inlet
fuel nozzle (1).
NOTE: Insert end of tube assembly without flats, into grooved end of fuel nozzle.
|
| (5) | Install 24 metal gaskets (11) on 23 fuel nozzles (2) and one inlet nozzle (1). |
| (6) | Put inlet nozzle (1) in combustor assembly, at bottom center location. Make sure nozzle enters combustion chamber liner. Install one bolt (10) fingertight. |
| (7) | Insert 21 secondary and 2 primary fuel nozzle assemblies (2) in combustor assembly. |
| (8) | Install bolts with solid heads (8 and 10) on secondary and inlet nozzles, fingertight. |
| (9) | Install 2 bolts (10) with drilled heads, one on each primary fuel nozzle, fingertight. Install each bolt on side without retaining plate. |
| (10) | Slide 24 fuel manifold tube assemblies (6) over fuel nozzles until retaining plate locking grooves are exposed. |
| (11) | Insert one tube retaining plate (9) into locking groove of inlet nozzle (1). Secure with one bolt (8) fingertight. |
| (12) | Insert remaining 23 tube retaining plates (9) into locking grooves in 23 fuel nozzles (2). Install remaining bolts fingertight. |
| (13) | Torque bolts (8 and 10) 36 to 40 lb.in. (4.0-4.6 Nm) at 48 places. |
| (14) | Visually inspect to make sure the gaskets are correctly installed and not pinched between the fuel nozzles and the combustion chamber. Rotate the combustion chamber, if necessary. |
| (15) | Secure bolts on primary fuel nozzles with lockwire (PWC05-089). |
| (16) | Do a leak check of the fuel manifold and nozzles (Ref. Adjustment/Test). |
| (1) | Put a new gasket (1) , (Fig. ) on drain tube (2) and install in bottom of combustor outer case. Torque 90 to 100 lb.in (10-11 Nm). |
| (2) | Pre-SB25039: Lockwire (PWC05-089) between drain tube (2) and combustor case lug. |
| (3) | Post-SB25039: Lockwire (PWC05-089) between drain tube (2) and lower bypass duct bracket (5) . |
| (4) | Install seal ring (12) , (Fig. ) on gas generator flange. |
| (5) | Center seal ring with four to six pieces of shim stock, 0.010 in. (0.25 mm) thick, equally spaced around gas generator case flange. Apply small amounts of bees wax (PWC06-015), at eight places minimum, to hold seal in place. |
| (6) | Remove shim stock. |
| (7) | Install sling (4) (PWC43022) on combustor outer case (6) and lower combustor over diffuser pipes until one inch of clearance exists between the combustor and gas generator case. |
| (8) | Install cooling ring set (PWC61012) with dry ice, and cool flange at combustor and gas generator case. |
| (9) | Lower combustor assembly into place aligning offset hole. Combustor should seat without force to prevent damage to seal ring. |
| (10) | Install four jacking insert blanking plates (3) on flange H at locations A with eight nuts (7) and bolts (8) . Tighten nuts (7) fingertight. |
| (11) | Install 72 bolts (10) and nuts (7) at unidentified locations. Tighten nuts (7) fingertight. |
| (12) | Pull down combustor by tightening nuts in a star pattern evenly in groups of four 62 to 72 lb.in. (7.0-8.0 Nm) until seated. |
| (13) | Remove sling from combustor assembly. |
| (14) | Align offset hole and install upper bypass duct bracket assembly (2) on combustion chamber outer case. Install eleven nuts (7) and bolts (9) at location B. Tighten 62 to 72 lb.in. (7-8 Nm). |
| (15) | Install lower bypass duct bracket assembly (5) with bottom center tab aligned with combustion chamber drain. Install nine nuts (7) and bolts (9), at location B. Tighten 62 to 72 lb.in. (7-8 Nm). |
| (16) | Secure drain tube (2) to bracket (7) with lockwire (PWC05-089). |
| (17) | Place rear support ring (13) over combustor. |
| (1) | Refer to Chapter 72-50-01. |
| Tool No. | Name |
|---|---|
| PWC60718 | Test Kit |
| (1) | Install plug (1) in main fuel passage. |
| (2) | Install inlet adaptor (3) in fuel inlet nozzle (2) and lock in place using locking clamp (4). |
| (3) | Connect the pressure test kit (PWC60718) to inlet adaptor (3). |
| (4) | Make sure test kit valve selector (6) is in the OFF/TEST position as shown in figure. |
| (5) | Make sure nitrogen regulator (7) is closed, if regulator it is not preset. |
| (6) | Open nitrogen gas tank and adjust regulator to 100 to 150 psi (689.5 to 1034.2 kPa), if regulator is not preset. |
| (7) | Turn valve selector (6) to COMBUSTOR position. Make sure gauge reads 100 to 150 psi (689.5 to 1034.2 kPa). |
| (8) | Turn test kit valve to the OFF /TEST position and turn nitrogen gas tank to OFF. |
| (9) | Monitor manifold pressure for 5 minutes minimum. No pressure drop allowed from manifold pressure gauge. |
| (10) | If pressure drop is noted, investigate source and rectify. |
| (11) | Re-test fuel manifold assembly after rectification. |
| (12) | Turn test kit valve to BLEED OFF position prior to tool removal. |
| (13) | Remove clamp, test adapter, plug and test kit upon completion of test. |
| (1) | Inspect for cracks. No cracks permitted. |
| (2) | Inspect for nicks or dents. Maximum of 15 acceptable to a depth of 0.003 inch (0.08 mm) provided damage is removed to a maximum depth of 0.005 inch (0.13 mm) and separated by a minimum distance of 0.250 inch. |
| (3) | Inspect igniter boss thread for damage. Minor damage may be removed by blending (Ref. 70-00-00 REPAIR). |
| (4) | Check for loose, broken or damaged jacking inserts. Replace as necessary (Ref. 70-00-00 REPAIR). |
| (5) | Check for loose, broken or damaged threaded inserts. Replace as necessary (Ref. 70-00-00 REPAIR). |
| (1) | For Pre-SB25108, the following conditions are acceptable:
|
| (10) | For Post-SB25108, the following conditions are acceptable (Ref. Fig. ):
|
| (27) | Burned through holes on combustion liner walls are not acceptable and require repair. |
| (28) | Fretting wear on floating collars:
|
| (1) | Inspect for cracks. No cracks permitted. |
| (2) | Inspect for fretting of sheath. Acceptable to 50 percent of wall thickness. |
| (3) | Inspect for burning or erosion of nozzle tip. Reject if damage evident on tip inner surface. |
| (1) | Inspect the external sheath of each igniter at Dia. A for chafing and wear. Replace
igniter if the following limits are exceeded:
|
| (4) | Inspect end face,View B for:
|
| Item No. | Name |
|---|---|
| PWC04-003 | Synthetic Grease |
| PWC05-018 | Pencil |
| PWC05-018A | Pencil |
| PWC05-066A | High Temperature Pressure Sensitive Tape |
| PWC05-293 | Crayon, Metal marking |
| PWC05-298 | Penetrating Fluid |
| PWC06-009 | Anti-seize Compound |
| PWC06-015 | Beeswax |
| PWC09-002 | Locking and Retaining Compound |
| PWC11-014 | Isopropyl Alcohol |
| PWC11-027 | Petroleum Solvent |
| Tool No. | Name | Application |
|---|---|---|
| PWC32514 | Lifting Eye | HPT Module |
| PWC37807 | Hydraulic Pump | Various |
| PWC40323 | Puller | Replaces PWC43205 |
| PWC40601 | Rod Adapter, Stubshaft | Replaces PWC40258 |
| PWC40653 | Adapter | Replaces PWC60842 |
| PWC40781 | Adapter, Dyno-Torque Wrench |
|
| PWC41050 | Wrench | HPT Module |
| PWC43057 | Pusher | HPT Module |
| PWC43206 | Drift | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC43209 | Puller | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC43215 | Base | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC43250 | Protector | HPT Module |
| PWC60101 | Adapter Ring | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC60102 | Gage | HPT Housing Assembly |
| PWC60136 | Controller | Various |
| PWC60152 | Platen | HPT Module |
| PWC60177 | Puller | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC60376 | Stand | HPT Module |
| PWC60377 | Revolving Ring | HPT Module |
| PWC60398 | Spacer | HPT/Shroud Housing Assembly |
| PWC60415 | Puller | HPT/Shroud Housing Assembly |
| PWC60418 | Puller | HPT Module |
| PWC60434 | Socket | HPT Module |
| PWC60435 | Adapter | HPT Module |
| PWC60437 | Drift | First-stage HPT Vane Assembly |
| PWC60440 | Fixture | Various |
| PWC60464 | Retainer | HPT Blades |
| PWC60474 | Base | First-stage HPT Vane Assembly |
| PWC60475 | Drift | First-stage HPT Vane Assembly |
| PWC60487 | Ring | HPT Housing Assembly |
| PWC60550 | Ring | HPT Housing Assembly |
| PWC60623 | Lifting Fixture | HPT Module |
| PWC60658 | Ring | HPT Module |
| PWC60719 | Support | HPT Module |
| PWC60731 | Fixture | HPT Module |
| PWC60738 | Fixture | HPT Housing Assembly |
| PWC60791 | Gage | HPT Spacer |
| PWC60805 | Protector | Various |
| PWC60810 | Drift | Second-stage Vane Ring |
| PWC60813 | Handle | Second-stage Vane Ring |
| PWC60818 | Puller/Pusher | First-stage HPT Assembly |
| PWC60841 | Base | First-stage HPT Vane Assembly |
| PWC60843 | Drift | Various |
| PWC60844 | Base | Second-stage Vane Ring |
| PWC60916 | Heater | HPT Module |
| PWC60923 | Adapter Plate | HPT Module |
| PWC61030 | Runout Fixture | HPT Module |
| PWC61034 | Base | First-stage HPT Vane Assembly |
| PWC61423 | Adapter | First-stage HPT Vane Assembly |
| PWC61544 | Assembly Fixture | First-stage HPT Vane Assembly |
| PWC61580 | Holder/Pusher | HPT Module |
| PWC61765 | Guide - HPT Assy | HPT Module |
| PWC61768 | Fixture | Second-stage Vane Ring |
| PWC61774 | Adapter | HPT Module |
| PWC61775 | Holder | HPT Module |
| PWC61790 | Fixture | First-stage HPT Vane Assembly |
| PWC61813 | Puller | First-stage HPT Vane Assembly |
| PWC61820 | Puller | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC61821 | Drift | No. 3 Bearing Rear Cover and Rotor Air Seal |
| PWC61823 | Pad | Various |
| PWC62400 | Base | First-stage HPT Vane Assembly |
| PWC62546 | Drift | First-stage HPT Vane Assembly |
| PWC64241-2 | Guide Pin | HPT Module |
| PWC64241-3 | Pin, Nose Cone Onto Fan | First-stage HPT Vane Assembly |
| PWC64330 | Cooling Ring | Obsolete - replaced by PWC89835 |
| PWC71392 | Adapter | Replaces PWC32505 |
| PWC89835 | Air Cooling Tool | Alternate to PWC64330 |
| PWC89837 | Cylinder, Hydraulic | Replaces PWC32506 |
| (1) | Measure the second-stage HP turbine disk radial tip clearance (RTC) at four locations equally spaced around shroud housing. Record as Dim. B. |
| (2) | Measure the second-stage HP turbine disk RTC :
|
| (7) | Locate the scallop in the stubshaft adjacent to the retaining nut and mark a line,
with an approved marker, on the HP turbine rear cover (4, Fig. ) in line with the scallop center line.
NOTE: This line marking will be used during the assembly of the HP turbine disk to return
the rotating assemblies to the original balanced position, i.e. in line with the scallop
on the stubshaft.
|
| (8) | Remove the retaining ring (1) and the keywasher (2) . |
| (9) | Soak the threads of the HP turbine retaining nut and compressor rotor stubshaft with penetrating oil (PWC05-298). Rotate the turbine several times, to allow the oil to penetrate the thread. Let oil soak for 30 minutes before trying to loosen nut. |
| (10) | Heat nut with a suitable heatgun for 30 minutes. |
| (11) | Install the support (PWC60719) on flange E with three bolts. |
| (12) | Install the socket (PWC60434) on the HP turbine cover and the adapter (PWC60435) over the socket and engage the anti-rotation scallop. |
| (13) | Install the anti-rotation adapter (PWC40781) and wrench (PWC41050) on socket and loosen the retaining nut (3) . |
| (14) | If the HPT retaining nut will not loosen, remove the adapter (PWC60435), the socket (PWC60434) and the support (PWC60719), and proceed as follows with the drilling fixture (PWC60731):
CAUTION: DO NOT USE HOLE IN LINE WITH EITHER OF TWO DIMPLES IN HPT NUT.
|
| (26) | Remove the tools and the retaining nut. |
| (27) | Locate the scallop in the stubshaft and mark a reference line on the HP turbine rear cover (4) in line with the scallop. Use an approved marker to mark the line. |
| (28) | Install adapter (6, Fig. ) (PWC71392), cylinder (7) (PWC89837), pad (4) (PWC61823) and puller (5) (PWC60418). |
| (29) | Connect pump (PWC37807) to cylinder, and remove the HP turbine cover (4, Fig. ). |
| (30) | Remove disassembly tools. |
| (31) | Locate the scallop in the stubshaft and mark a line on the
second-stage HP turbine disk (5)
in line with the scallop center line on the stubshaft. Use an approved marker to
mark the line.
NOTE: This line marking will be used during the assembly of the HP turbines to return
the rotating assemblies to the original balanced position, i.e. in line with the scallop
on the stubshaft.
|
| (32) | Remove the second-stage shroud segment retaining ring (11) . |
| (33) | Install reaction pad (4, Fig. ) (PWC61823). |
| (34) | Install split body of puller (5) (PWC60415) over lip of second-stage turbine disk (5, Fig. ). |
| (35) | Install sleeve of puller over split-body. |
| (36) | Install lifting fixture (2) (PWC60623) to HP turbine module as follows:
|
| (42) | Install lifting eye (PWC32514) and lifting arm (1). |
| (43) | Support fixture (2) (PWC60623) with engine hoist or chain block. |
| (44) | Screw cylinder (7) (PWC89837) into adapter (6) (PWC71392). |
| (45) | Install adapter (6) (PWC71392) on end of puller. Make sure lock of adapter aligns with the word “LOCK” on puller. |
| (46) | Attach pump (PWC37807) to cylinder (7) (PWC89837). |
| (47) | Apply pump pressure to puller and slowly remove HP turbine module. When the front face of the HP first-stage turbine disk (7) , (Fig. ) is accessible, move the safety arms of the lifting fixture in position and install pin. |
| (48) | Carefully lower turbine assembly or assemblies onto fixture (PWC60440). |
| (49) | Remove seal ring (8) , (Fig. ) from first-stage HP turbine vane. |
| (50) | Install protector (PWC43250) over shaft. |
| (1) | If the first-stage HP turbine assembly remains in the engine after the second-stage
HP turbine assembly is removed, proceed as follows:
|
| (1) | Measure the first-stage HP turbine disk radial tip clearance:
|
| (6) | Put holding fixture (7) (PWC60440) on bench, push two holding arms in to center of fixture, and put HP turbines and housing assembly on holding fixture. |
| (7) | Mark a line on the first-stage HP turbine disk in line with the marking on the second-stage
HP turbine disk done on the previous operation. Use an approved marker to mark the
line.
NOTE: This line marking will be used during the assembly of the HP turbines to return
the rotating assemblies to the original balanced position, i.e. in line with the scallop
on the stub shaft.
|
| (8) | Install reaction pad (2) (PWC61823), spacer (4) (PWC60398), puller (3) (PWC60415), adapter (8) (PWC71392) and cylinder (1) (PWC89837). |
| (9) | Connect pump (PWC37807) to cylinder and apply pressure to disengage the two disks. |
| (10) | Install retainer (PWC60464) and remove second-stage HP turbine disk assembly (5) . |
| (11) | Remove HP turbine housing. |
| (12) | Push holding arms into the center of the holding fixture, until two clamps disengage from first-stage HP turbine (6) . |
| (13) | Remove first-stage HP turbine (6) from holding fixture. |
| (14) | Place the removed parts in separate containers. |
| (1) | Remove shroud retaining ring (11) . |
| (2) | Remove No. 1 shroud segment (9) from turbine housing (5) by lifting segment up to disengage the locking feature. |
| (3) | Pull segment into center of turbine housing. |
| (4) | Remove remaining segments (9) and seals (10) . |
| (5) | Remove retaining ring (8) . |
| (6) | Remove second-stage vane assembly (7) and piston seal (6) . |
| (7) | Remove 24 first-stage shroud segments (3) and 24 seals (2) . |
| (8) | Remove seal (1) . |
| (1) | Put an index mark, with an approved marker, at 12 o'clock position across both bolting flanges of the first-stage HPT vane. |
| (2) | Pre-SB25108:
|
| (5) | Post-SB25108:
|
| (8) | Install three slave nuts and bolts (3) to fasten vane assembly together. |
| (1) | Remove bolts (5) and nuts (4) if installed (Ref. Section B-B). |
| (2) | Number all vane segments (2) (Ref. View C), with an approved marker, from 12 o'clock counterclockwise. |
| (3) | Install and fasten first-stage HP turbine vane assembly (2) on base (12). |
| (4) | Install drift (11) on first-stage HP turbine vane assembly (2). |
| (5) | Install cylinder (10) to drift (11) and pump (PWC37807) to cylinder. |
| (6) | Put some dry ice in the cavity area on the first-stage HP turbine vane assembly (2) and slowly apply 1000 psi pressure on the drift (11). |
| (7) | Remove HP turbine disk air nozzle assembly (3) . |
| (8) | Post-SB25211: Gently tap the HP turbine stator front inner support (13) with a soft faced hammer to remove from the HP turbine disk air nozzle assembly (3). |
| (9) | Remove vane segments (2) from fixture, turn vane over and remove
HP turbine stator inner support (6)
with suitable soft faced hammer.
NOTE: If the HP turbine stator inner support (6) cannot be removed with suitable soft
faced hammer, then the inner shroud removal fixture (PWC61790) may be used.
|
| (10) | Install HP Turbine vane outer shroud (1) on base (PWC61034). |
| (11) | Remove vane segments (2), inner air seals (7) and outer air seals (8) . |
| (12) | Remove air seal (9) (Ref. Detail A). |
| (1) | Identify the 12 o'clock position of the outer shroud by applying a temporary "X" mark on the lug adjacent to the anti-rotation slot with an approved marker (PWC05-018A). |
| (2) | Put HP turbine vane outer shroud (1) in the oven at 177 to 204°C (350 - 400°F) for 15 to 30 minutes. |
| (3) | Put air seal (9) in freezer at -40°C (-40°F) for 15 to 30 minutes. |
| (4) | Install air seal (9) on HP turbine vane outer shroud assembly (1), as shown (Ref. Detail A). |
| (5) | Install 10 vane assemblies (2) without the seals (7) and (8) starting with vane No. 1 in line with the index mark at the 12 o'clock position. |
| (6) | Install the remaining nine numbered vane assemblies in consecutive order, counterclockwise direction. |
| (7) | Keep a zero gap setting on all the HP turbine vane assemblies except between segments No. 5 and No. 6, as shown. |
| (8) | Measure the gap by measuring the gap between vane assemblies No. 5 and No. 6. |
| (9) | The minimum gap permissible is 0.110 inch (2.79 mm). |
| (10) | Remove all the vane assemblies from the outer shroud. |
| (11) | Install 10 vane outer air seals (8) and 10 vane inner air seals (7) in first-stage HPT vane assemblies (2) (Ref. View C). Hold air seals in place with synthetic grease (PWC06-015). |
| (12) | Identify the offset holes on the
turbine disk air nozzle (3)
and
inner support (6)
by marking an "X" adjacent to the offset holes with an approved marker (PWC05-18A).
NOTE: Due to the minimal offset distance, the offset hole on the air nozzle is not readily
visible and can only be determined with a suitable measuring device. The offset hole
on the inner support is a smaller diameter than the other twenty-three holes and has
an electro-etched "X" adjacent to the hole.
|
| (13) | Install No. 1 segment in the outer shroud (1) and align the vane lug with the shroud slot in line with the index mark. |
| (14) | Install vane segments on each side of No. 1 segment seals. No gap between each segment until all segments are in and a gap remains at the bottom as shown. |
| (15) | Engage seals at gap and move outward until correctly seated in outer shroud. Make sure that seals are correctly installed between each vane segment by slightly separating vanes one at a time and confirming seals are properly engaged and have not been damaged. |
| (16) | Install 0.011 to 0.023 inch (0.28 - 0.58 mm) shim between each vane segment to keep gap during assembly. |
| (17) | Put vane assembly (2) in oven at 177 to 204°C (350 - 400°F) for 15 to 20 minutes. |
| (18) | Pre-SB25104:
WARNING: USE HEAT RESISTANT GLOVES WHEN HANDLING HOT PARTS.
CAUTION: MAKE SURE THAT THE CHAMFERS OF VANE AND INNER SHROUDS ARE ALIGNED.
WARNING: PUT ON PROTECTIVE GLOVES WHEN HANDLING HOT PARTS TO PREVENT PERSONAL INJURY.
CAUTION: MAKE SURE HP TURBINE DISK AIR NOZZLE ASSEMBLY IS SEATED EVENLY ON HP TURBINE VANE
ASSEMBLY.
|
| (25) |
Post-SB25104/Pre-SB25211:
WARNING: PUT ON PROTECTIVE GLOVES WHEN HANDLING HOT PARTS TO PREVENT PERSONAL INJURY.
CAUTION: MAKE SURE THAT THE CHAMFERS OF THE HP TURBINE VANE ASSEMBLY AND THE HP TURBINE STATOR
INNER SUPPORT ARE ALIGNED.
WARNING: PUT ON PROTECTIVE GLOVES WHEN HANDLING HOT PARTS TO PREVENT PERSONAL INJURY.
CAUTION: MAKE SURE HP TURBINE DISK AIR NOZZLE ASSEMBLY IS SEATED EVENLY ON HP TURBINE VANE
ASSEMBLY.
|
| (36) | Post-SB25211:
WARNING: PUT ON PROTECTIVE GLOVES WHEN HANDLING HOT PARTS TO PREVENT PERSONAL INJURY.
CAUTION: MAKE SURE THAT THE CHAMFERS OF THE HP TURBINE VANE ASSEMBLY AND THE HP TURBINE STATOR
REAR INNER SUPPORT ARE ALIGNED.
WARNING: PUT ON PROTECTIVE GLOVES WHEN HANDLING HOT PARTS TO PREVENT PERSONAL INJURY.
CAUTION: MAKE SURE THAT THE CHAMFER EDGE OF THE HP TURBINE STATOR FRONT INNER SUPPORT IS
FACING DOWN WHILE INSTALLING.
CAUTION: MAKE SURE THAT THE LUGS ARE ENGAGED BEFORE INSTALLING HP TURBINE VANE ASSEMBLY.
WARNING: PUT ON PROTECTIVE GLOVES WHEN HANDLING HOT PARTS TO PREVENT PERSONAL INJURY.
CAUTION: MAKE SURE VANE IS SEATED EVENLY.
|
| (54) | Apply 1800 to 2000 psi (12,410.5 - 13,789.5 kPa) pressure and keep pressure until assembly reaches room temperature. |
| (55) | Install three equally spaced slave bolts (5) and nuts (4) . |
| (56) | Torque nuts 36 to 40 lb.in. (5.5 - 6 Nm). |
| (57) | Install shims at 10 places at location G. Shim thickness ranges from 0.011 to 0.023 inch (0.28 - 0.58 mm). |
| (58) | Measure gaps at locations G between HP turbine vane segments at 10 places with shim stock. Check minimum and maximum gap. |
| (59) | Remove all shims after checking the gaps. |
| (60) | Examine the alignment of the HPT vane cooling passage relative to the large holes in the HPT vane shroud vane. Make sure there is no misalignment with the HPT outer shroud which could cause partial occlusion of the airfoil cooling passage way. |
| (61) | Do a check of the vane assembly flow area (F&C REF. NO. 1851) if a facility is available
to perform this check.
NOTE: To recover engine performance loss due to compressor deterioration, a flow area
lower than 11.60 sq. in. is acceptable, providing the engine does not surge during
handling test.
|
| (1) | Install 2 alignment pins (1) (PWC64241-3) at the
turbine disk air nozzle support location (2)
.
NOTE: Do not use the offset hole at the TDC location.
|
| (2) | Install 2 alignment pins (1) at the combustion liner location. |
| (3) | Install the heating adapter (PWC61423). |
| (4) | Install the vane (3) on the adapter. |
| (5) | Set the temperature control on the controller (PWC60136) to 400°F (204°C). |
| (6) | Set the selector switch 'TOOL/PLATEN' to PLATEN. |
| (7) | Set the controller power switch to ON. |
| (8) | Set the timer to 20 minutes. |
| (9) | Press HEATER START and TIMER START. |
| (10) | At sound of timer alarm select RESET. |
| (11) | Set controller power switch to OFF. |
| (12) | Pre-SB25108: Install vane assembly with X mark at 12 o' clock and offset hole(s) aligned (F&C REF. NO. 1386). |
| (13) | Post-SB25108:
|
| (17) | Make sure the assembly is installed within 30 seconds of removal from adapter. |
| (18) | Remove guide pins (1). |
| (19) | Coat all bolt (4) threads with anti-seize compound (PWC06-009). |
| (20) | Install 24 bolts (4). Tighten 43 to 47 lb.in. (4.8-5.3 Nm). |
| (21) | Install 24 bolts (5) . Tighten 36 to 40 lb.in. (4.1-4.5 Nm). |
| (22) | Allow assembly (3) to cool to room temperature and tighten bolts (4), 43 to 47 lb.in. (4.1-4.5 Nm). |
| (1) | Remove HP turbine air seal (14) together with the spacer (15) (if spacer has not been removed yet) with puller (PWC60177). |
| (2) | Remove retaining ring (7). |
| (3) | Remove HP turbine rotor brush seal (8) with puller (PWC61820). |
| (4) | Remove six bolts (9) fastening bearing cover to gas generator/diffuser case (1). |
| (5) | Remove No. 3 bearing rear cover (10) with puller (PWC43209). |
| (6) | Inspect carbon seal (6) for damage (Ref. INSPECTION/CHECK). If no damage is present, do not remove carbon seal from rear cover assembly. |
| (7) | If damage is found proceed as follows:
CAUTION: HANDLE CARBON SEAL WITH CARE. ROUGH HANDLING CAN CAUSE DAMAGE OR RESULT IN AN OUT
OF ROUND CONDITION.
|
| (1) | Put No. 3 bearing rear cover assembly (10) in oven preheated to 350 to 400°F (177-204°C) for 15 to 30 minutes. |
| (2) | Place carbon seal (6) in freezer at -40°F (-40°C) for 15 to 30 minutes. |
| (3) | Put support base (PWC43215) on arbor press. |
| (4) | Remove No. 3 bearing rear cover (10) from oven and place it on support base (PWC43215). |
| (5) | Remove carbon seal (6) from freezer and apply locking compound (PWC09-002) in area B. |
| (6) | Install carbon seal assembly in rear cover assembly (10) with snap washer (11) down,
with drift (PWC43206). Make sure carbon seal was not damaged during installation. Remove excessive locking
compound.
NOTE: Install seal within 60 seconds after removing from freezer.
|
| (7) | Fasten carbon seal (6) in rear cover (10) with retaining ring (3). |
| (8) | Put No. 3 bearing rear cover assembly (10) in a clean sealable container identified with the engine serial number. |
| (1) | Clean faces and spigots of both parts with alcohol (PWC11-014) with a lint free wiper prior to assembly. |
| (2) | Heat flange of gas generator case for 15 minutes with a hot air heat gun. |
| (3) | Install two guide pins (PWC64241-2) equally spaced around flange. |
| (4) | Lubricate and install one new preformed packing (4) on No. 3 bearing rear cover assembly (10) . |
| (5) | Put a thin film of oil on face of carbon seal (6) . |
| (6) |
Install No. 3 bearing rear cover (10) on gas generator case (1) aligning offset hole.
Make sure locating pins (13) on the oil housing engage with cover before seating the
cover.
NOTE: A dental mirror can be used to check for engagement of locating pins with cover.
|
| (7) | Gradually seat No. 3 bearing rear cover assembly (10) with three bolts (9) . Remove guide pins. |
| (8) | Tighten six bolts (9) in a star pattern 36 to 40 lb.in. (4-4.6 Nm). |
| (9) | Allow assembly to reach room temperature then and check tighten 36 to 40 lb.in. (4-4.6 Nm). |
| (1) | Check that the wire damper seal (16) is installed. |
| (2) | Heat seal (14) evenly, in area C, for 15 to 20 minutes with suitable heatgun. |
| (3) | Install seal on stubshaft (12) , aligning V mark of seal (14) and stubshaft scallop. |
| (4) | Seat seal (14) on stubshaft with adapter (PWC40653), drift (PWC60843), hydraulic pump (PWC37807), and hydraulic cylinder (PWC89837). |
| (5) | Apply 1400 to 1500 psi (9652.6-10342.1 kPa) pressure. Hold pressure or 5 to 10 minutes until temperatures stabilize. |
| (6) | Remove tools. |
| (1) | Place the brush seal (1) in a freezer for 15 to 30 minutes at -40°F (-40°C). |
| (2) | Locally heat inside diameter of air nozzle support assembly (3) for ten minutes with a suitable heat gun. |
| (3) | Remove brush seal (1) from the freezer and install in the air nozzle support assembly (3) with drift (2) (PWC61821). Make sure anti-rotation lug is aligned with slot of brush seal carrier. |
| (4) | Maintain pressure until parts temperature have equalized. Make sure seal has seated correctly. |
| (5) | Install retaining ring (4) . |
| (1) | Select first-stage and second-stage shroud segments which require replacing. Select
same class of shroud segments which are being replaced, to suit turbine dimension
(Table 602 REF. NO. 1225). Layout shroud segments and mark the new shroud segments.
NOTE: Note direction of arrow on No.1 segments for first- and second-stage segments.
|
| (2) | Check for index mark X at offset hole of shroud housing on each side of flanges. |
| (3) | Mask cooling holes of HPT shroud housing, area S, with tape (PWC05-066A). Make sure tape does not interfere with shroud installation for grinding. |
| (4) | Install shim stock of equal thickness in each rail location FG1. Chose thickness, start with 0.003 inch, that lets segment fit snug. Reduce or increase as necessary. |
| (5) | Start with No. 1 segment (2) of first-stage shroud in line with offset hole, and install segment with shim stock between segment rails and housing. |
| (6) | Installing remaining segments in CCW direction in same manner. |
| (7) | Install slave retaining ring (3) (PWC60487). |
| (8) | Install shim stock of equal thickness in each rail location FG2. Chose thickness, start with 0.003 inch, that lets segment fit snug. Reduce or increase as necessary. |
| (9) | Start with No. 1 segment (4) of second-stage shroud in line with offset hole, and install segment with shim stock between segment rails and housing. |
| (10) | Install remaining segments in CW direction in same manner. |
| (11) | Install HPT housing in grinding fixture as follows.
|
| (1) | Install adapter ring (2) (PWC60101) on flange E of
combustion chamber outer case (1)
, aligning offset hole at top. Install four slave 0.250 inch diameter nuts and bolts.
Tighten 85 to 95 lb.in. (9.6-10.7 Nm).
NOTE: Make sure runout fixture spigot is engaged fully and spigot is seated.
|
| (2) | Install runout gage (4) (PWC60102) on stubshaft (6) . Install nut (5) hand tight. |
| (3) | Put DTI (3) at top center and set to zero. |
| (4) | Turn stubshaft (6) clockwise, two full turns, to make sure DTI returns to zero at top center (Ref. View F). |
| (5) | Check dial indicator readings at A, B, C and D and record results.
|
| (11) | Note positive and negative signs of dial indicator. |
| (12) | Make sure position A returns to zero when each reading is taken. |
| (13) | If runout exceeds plus or minus 0.005 inch at position B or D, or if runout exceeds plus 0.009 inch or minus 0.001 inch at position C, remove combustor and check seal for damage and re-seat combustor assembly. |
| (14) | Remove runout gage (4) and adapter ring (2). |
| (1) | Calculate offset, X horizontal axis or Y vertical axis, for grinding of shroud segments
recorded in preceding (Ref. step ) with positive and negative signs as follows:
|
|||||||||||||||
| (2) | Example in view No. 5 is described as follows:
|
|||||||||||||||
| (3) | Record X and Y offset values, and determine the location of material removal. |
| (1) | Install holding fixture on grinding machine. |
| (2) | Adjust holding fixture to offset grind to requirements (Ref. Para. ). |
| (3) | Grind first-stage shroud segments to Dim. (Ref. Table 602 REF. NO. 1225). Check for witness steps after grinding. |
| (4) | Grind second-stage shroud segments to Dim. (Ref. Table 602 REF. NO. 1225). Check for witness steps after grinding. |
| (5) | Remove HP turbine housing assembly from grinding fixture. |
| (1) | Remove slave bolts and nuts from shroud housing and grinding fixture. |
| (2) | Remove shroud housing from grinding fixture with jacking screws. |
| (3) | Remove second-stage shroud segment retaining ring (5) and remove second-stage shroud segments (4) and shim stock from location FG2. |
| (4) | Remove first-stage shroud segment slave retaining ring (3) and remove first-stage shroud segments (2) and shim stock from location FG1. |
| (5) | Spray wash all components with solvent (PWC11-027). |
| (6) | Remove all masking tape from area S. |
| (7) | Remove all tape residue with clean cloth dampened in solvent (PWC11-027). |
| (8) | Spray wash again with solvent (PWC11-027) and dry with dry compressed air. |
| (1) | Install support ring (PWC60550) in shroud housing. |
| (2) | Install piston seal ring and check gap as follows:
|
| (1) | Install seal (1) in shroud housing (10) . |
| (2) | Mark location of No. 1 first-stage shroud segment anti-rotation slot (12) in area E with silver pencil (PWC05-018). |
| (3) | Mark location of shroud housing No. 1 first-stage anti-rotation pins (12) location in area F with silver pencil (PWC05-018). |
| (4) | Install segment seal (3) on CCW side of segment. |
| (5) | Install remaining shroud segments (2) in CCW direction from No. 1 at index mark. |
| (6) | Install shroud segment in rails joining each segment together tightly as possible to allow installation of last segment. |
| (7) | Separate each segment enough to align housing anti-rotation pins with segments anti-rotation slots. |
| (8) | Tap segments gently down with soft faced hammer until they are completely seated and install piston seal (4). If segments do not seat, remove and check seal for damage. Replace seal if required. |
| (9) | Record second-stage vane class number. If class number is not indicated, record vane area. |
| (10) | Install protector (PWC60805) on brush seal. |
| (11) | Install piston seal (4) in second-stage vane assembly. |
| (12) | Install second-stage vane assembly (5) . Make sure lugs go into mating slots of housing with smaller lug marked X installed in smaller slot of housing marked X. |
| (13) | Install retaining ring (6) . |
| (14) | Mark location of No. 1 second-stage shroud segment anti-rotation slots (11) in area C with silver pencil (PWC05-018). |
| (15) | Mark location of shroud housing No. 1 second-stage shroud segment anti-rotation pin (11) in area D with silver pencil (PWC05-018). |
| (16) | Install segment seal (3) on CW side of segments. |
| (17) | Install remaining segments (7) and seals (8) in cw direction from No. 1 segment. |
| (18) | Install shroud segments in rails joining each segment together as tightly as possible to allow installation of last shroud segment. |
| (19) | When all segments are installed join the last segment to the first segment. Separate each segment enough to align anti-rotation pins with anti-rotation slots. |
| (20) | Tap segments gently with soft faced hammer until all segments are completely seated. Install retaining ring (9) . |
| (1) | Install HPT gage (1) (PWC60791) on HP rotor shaft (2) . Make sure adapter touches rear face of HP turbine rotor air seal (5) . |
| (2) | Measure the distance from the front face of the HP turbine first-stage disk (3) to the front of the turbine blade (4) platform. Record value as dimension GH. |
| (3) | Make sure HP rotor is turning freely and is loaded forward by pushing shaft with the hand during the measurement process. |
| (4) | Measure distance from rear face of spacer gage to the rear face of the HP turbine stator air seal at 4 equally spaced locations. Take the minimum value and record as dimension GV. |
| (5) | Dimension HH = Dimension C - dimension GV, where dimension C is marked on tool (Ref. 6.5XX). |
| (6) | Spacer thickness = Dim. HH - Dim. GH + 0.051 inch. |
| (7) | Select pre-ground spacer or grind new replacement spacer (Ref Subpara. following) to above requirements. |
| (1) | Grind Face D only to achieve required thickness ± 0.001 inch and surface finish of 63 micro inches. |
| (2) | Spacer faces must be flat within 0.002 inch and Face D must be parallel to Face B within 0.0002 inch. |
| (3) | Break edges of spacer 0.003 to 0.015 inch. |
| (4) | Magnetic particle inspect: rod 1000 amps. No cracks are permitted. |
| (5) | Spray wash spacer with solvent (PWC11-027) and air dry. |
| (6) | Check for residual magnetism with a standard field gage. Remove any residual magnetism. |
| (7) | Tag identify with thickness and seal spacer in plastic bag. |
| (1) | Remove retaining ring (3) . |
| (2) | Install vane assembly (1) in base (PWC60844). |
| (3) | Remove brush seal (2) with drift (PWC60810) and handle (PWC60813). |
| (1) | Load the compressor rotor stubshaft (3) forward and make sure that it is rotating freely. |
| (2) | Install gage (1) (PWC60791) on stubshaft. |
| (3) | Measure dimension TF with a suitable depth micrometer, at four equally spaced locations. |
| (4) | Record the average value. |
| (5) | Actual dimension, marked on gage, - TF = FS. |
| (6) | Pre-SB25104: Calculate dimension Z. Where Z = FS - (G + M1 + 0.045 + 0.125 + M2), as follows:
|
| (10) | Post-SB25104: Measure the dimension "B" at four equally spaced locations and record the average
value.
|
| (20) | Record dimension Z. |
| (21) | Install second-stage stator baffle on vane ring machining fixture (6) (PWC61768) and machine to dimension Z. |
| (22) | Measure and record the actual dimension. |
| (23) | Spray wash all components with (PWC11-027). Dry with dry compressed air. |
| (1) | Install revolving ring (PWC60377) on stand (PWC60376). |
| (2) | Install adapter plate (PWC60923) and fixture (1) (PWC60440) on ring (PWC60377). |
| (3) | Install second-stage, HPT2, disk assembly (6) in blade retainer. |
| (4) | Install setting ring (4) (PWC60658). |
| (5) | Install seal ring (5) below the bevel of the housing with P/N up, and joint in line with offset hole. |
| (6) | Check gap C between OD of seal ring and ID housing (Ref. Fits and Clearances REF. NO. 1806). |
| (7) | Make sure that mating surfaces of HPT1 disk and HPT2 disk are clean. |
| (8) | Pre-SB25104: Heat HPT2 disk mating spigot, area B, to 500°F (260°C) for 20 minutes with suitable heat gun. |
| (9) | Post-SB25104: Heat HPT2 disk mating spigot, area B, on heating platen (PWC60152) to 400°F (204°C) for 10 to 15 minutes. |
| (10) | Install HPT1 disk (2) on fixture (1) (PWC60440). |
| (11) | Install shroud housing (3) on fixture (1), aligning marked hole of shroud housing with similar index mark on HPT1 disk (2), and engaging anti-rotation lugs/slots. |
| (12) | Install HPT2 disk (6), aligning marked hole of shroud housing with similar index mark on HPT1 disk (2), and engaging anti-rotation lugs/slots. |
| (13) | Do not force HPT2 disk (6) to seat. If assembly does not seat correctly, repeat steps thru . |
| (14) | Rotate HPT2 disk CW as viewed from TE, aligning lines in bores of HPT1 and HPT2 disks. |
| (15) | Install pusher (8) (PWC43057) and cylinder (9) (PWC89837). |
| (16) | Connect pump (PWC37807) to cylinder (9), apply 1800 to 2000 psi (12,410.5-13789.5 kPa) pressure, and hold for five minutes minimum. |
| (17) | Disconnect pump, and remove cylinder (9) and pusher (8). |
| (18) | Make sure the TDC line of disk aligns with TDC line on stub shaft. |
| (1) | Remove shroud housing retaining ring (1, Fig. ), tag and identify ring with engine S/N. |
| (2) | Install pusher (2) (PWC61580) on HPT, aligning split line of pusher with index mark of HPT2. |
| (3) | Loosen shroud holders (4) and move inward. |
| (4) | Loosen screws (5) of shroud holders (4) but do not remove. |
| (5) | Move locator (6) away from HPT1. |
| (6) | Install fixture (3) (PWC60623) over pusher (2), aligning index mark of fixture with index mark on HPT. |
| (7) | Install nut (7) handtight only. Make sure top of nut is flush with top of pusher. |
| (8) | Tighten locator (6) against HPT2. |
| (9) | Adjust shroud holders (4) to align squarely in retaining ring groove. |
| (10) | Align shroud housing index mark with HPT assembly index mark and tighten shroud holders (4) handtight. |
| (11) | Install lifting eye (8) (PWC32514) to fixture (3) and install lifting hook into eye. |
| (12) | Lift and rotate assembly horizontal, and remove fixture (1, Fig. )(PWC60440). |
| (13) | Install safety arms (9, Fig. ) on fixture (3). |
| (14) | Align marked hole of HPT shroud housing, split of pusher (2), index mark of HPT2 and fixture (1, Fig. ). |
| (15) | Install heater (10, Fig. ) (PWC60916) and controller (11) (PWC60136) into bore of HP assembly, and set timer for twenty minutes. |
| (16) | Clean HPT spacer (12), mating surfaces of HPT1 disk and balancing piston with alcohol (PWC11-014). |
| (17) | Pre-SB25345: Install the HPT spacer (12) of correct thickness. |
| (18) | Post-SB25345: Select the class of new HPT sleeve spacer to fit within ± 0.001 inch during assembly (Ref. F&C REF. NO. 1284). If needed, grind the new HPT sleeve spacer to required dimension (Ref. Para ). |
| (19) | Install seal ring (13), with S/N forward, and split at top. Make sure scallop of seal ring aligns with anti-rotation pin of first-stage vane ring outer shroud seal ring groove. |
| (20) | Apply sealant (PWC09-002) maximum one drop, to seal ring joint, compress ring and hold until set. Seal ring must rotate freely in groove. |
| (21) | If sealant has spread between ring and groove, or does not set properly, remove ring, clean and re-apply sealant. |
| (22) | Make sure that the first-stage shroud segments are positioned rearward. |
| (23) | Install gasket (14). |
| (24) | Align index scallop of stubshaft with index mark on combustor case. |
| (25) | Install guide (PWC61765) into stubshaft bore with alignment pin in stubshaft scallop. |
| (26) | Check temperature of HPT spigot with probe of controller (11). If temperature is above 300°F (149°C), remove heater (10), store and lock safety arms (9). |
| (27) | Install HPT assembly aligning index mark with stubshaft scallop. Check that offset holes of shroud and combustor are aligned. |
| (28) | Remove guide from stubshaft. |
| (29) | Remove the spherical nut from the adapter (PWC40601) (15) threaded rod.
NOTE: The spherical nut is depicted in view of cylinder (PWC89837) (17).
|
| (30) | Insert adapter (PWC40601) (15) through the turbine module and install it on the stubshaft. Tighten the adapter on the stubshaft. |
| (31) | Install pusher pad (PWC43057) (16) and the hydraulic cylinder (PWC89837) (17) on the adapter (PWC40601) (15). |
| (32) | Install and tighten the spherical nut on the adapter (PWC40601) (15) threaded rod. |
| (33) | Install the hydraulic cylinder (PWC89837) (17) containment. |
| (34) | Attach the pump (PWC37807) to cylinder (17), and apply 2900 to 3100 psi (19994 - 21373 kPa) pressure. Hold for minimum five minutes. Remove tools. |
| (35) | Install retaining ring (18). |
| (36) | Install bolts (19) and nuts (20) around flange. Draw flanges together evenly by gradually tightening nuts (20) in a diametrically opposite clockwise pattern, starting at 12 o'clock, until flanges are seated. Finally torque all nuts 85 to 95 lb.in. (9.5-10.75 Nm). |
| (37) | Remove all tools. |
| (1) | Measure YY dimension on the cover (1) . |
| (2) | Record dimension YY. |
| (3) | Measure XX dimension on the HPT disk (2) and stub shaft (3) with a depth vernier. |
| (4) | Record dimension XX. |
| (1) | Make sure stubshaft scallop is at the 12 o'clock position. |
| (2) | Make sure that mating faces of HP rear cover (1) and HPT2 disk are clean. |
| (3) | Place rear cover on heater adapter (PWC61774) and set temperature to 600°F (315°C) for fifteen to thirty minutes. |
| (4) | Make sure cover temperature is more than 450°F (232°C), and install holder (PWC61775) on cover. |
| (5) | Install cover (1) with holder, aligning cover index mark with stubshaft index scallop. |
| (6) | Install drift (PWC60843), adapter (PWC40601) and cylinder (PWC89837). |
| (7) | Attach pump (PWC37807) to cylinder, and apply 3600 to 4000 psi (24,821-27,579 kPa). |
| (8) | Hold pressure. Let cover temperature equalize with cooling ring (PWC64330) or air cooling tool (PWC89835). |
| (9) | Remove tools. |
| (10) | Coat mating face and threads of nut (2) with anti-seize compound (PWC06-009) and install nut on shaft. |
| (11) | Install wrench (PWC41050), adapter (PWC60435) and socket (PWC60434). |
| (12) | Torque nut 2400 to 2640 lb.in. (271.2-298.3 Nm). |
| (13) | Hold torque and set angle needle to zero. |
| (14) | Turn nut thru angle of 50 degrees. |
| (15) | Trial fit keywasher. If slots do not align, increase angle of turn until slots align. Do not exceed 55 degrees total. |
| (16) | Record final torque value and angle. |
| (17) | Remove tools. |
| (18) | Install runout fixture (PWC61030) and check runout on face B. Maximum runout is 0.001 inch (0.03 mm). |
| (19) | Remove tools. |
| (20) | Install keywasher (4) . |
| (21) | Install retaining ring (3) with gap at 12 o'clock. |
| (1) | Measure and record dimension "ZZ". |
| (2) | Calculate stretch as follows:
|
| (4) | The amount of stretch must be 0.006 to 0.008 in. (0.152 - 0.203 mm). |
| (5) | If the stretch value is below the minimum limit, apply torque of 500 lb.ft. (6000 lb.in.) (677.9 Nm). Check stretch. |
| (6) | If the stretch is still under minimum, apply torque in 10 lb.ft. (120 in.lb.) (13.6
Nm) increments until the required stretch is achieved.
NOTE: Do not exceed 550 lb.ft. (6600 lb.in.) (745.7 Nm).
|
| • | Chapter 05-20-00 - Scheduled Maintenance Checks. |
| • | Chapter 75-30-01 - Compressor Bleed Valves - Maintenance Practices. |
| Item No. | Name |
|---|---|
| PWC06-009 | Compound, Antiseize |
| Tool No. | Name |
|---|---|
| PWC54101 | Gauge, HP Vane |
| (1) | Examine for cracks. No cracks permitted, reject assembly if evident. |
| (2) | Nicks, dents, scratches, scores, and corrosion pitting are acceptable to 0.005 inch (0.138 mm) deep on disk side face except for area located within 0.030 of fir tree fixings, and disk bore where 0.003 inch (0.08 mm) is acceptable. Remove sharp edges. Polish to restore surface finish. |
| (3) | Examine internal splines for pitting, wear and local surface damage. Isolated pitting or wear 0.005 inch (0.14 mm) deep is acceptable on 25 percent of surface. Remove sharp edges. |
| (4) | Examine the threads for wear and local surface damage. Fretting wear and galling 0.003 inch (0.08 mm) deep is acceptable. Remove sharp edges. Polish to restore surface finish. |
| (5) | Examine for signs of hot gas ingestion or overtemperature at the apex of fir tree fixings. White color indicates overtemperature. Send HPT disk assembly to overhaul facility if evident. |
| (1) | Examine balance counterweights retaining rivets for tightness. Replace as necessary. |
| (2) | Examine for cracks. No cracks permitted. Reject assembly if evident. |
| (3) | Nicks, dents, scratches, scores, and corrosion pitting are acceptable to 0.003 inch (0.076 mm) deep. Remove sharp edges. Polish to restore surface finish. |
| (4) | Examine knife edges for rubbing. If evident, check dimensions of knife edges:
|
| (5) | Examine for damaged cooling holes. No damage is permitted, reject assembly if damage is evident. |
| (6) | Examine for blocked cooling holes. Clear as necessary. |
| (1) | Airfoil tip, area j:
|
| (7) | Airfoil leading edge tip, area h:
|
| (10) | Airfoil leading edge, area f:
NOTE: Area f extends 0.100 inch (2.54 mm) from leading edge.
|
| (14) | Examine airfoil leading edge under blade platform for sulphidation. A narrow band , 0.080 inch (2.03 mm) wide maximum, occurring at the seal contact area on the platform, less than 0.020 inch (0.51 mm) below the platform, not associated with cracks or rubbing is acceptable. |
| (15) | Examine airfoil surface, area e for nicks, dents or pits. A maximum of three areas of damage 0.003 inch (0.08 mm) deep is acceptable. |
| (16) | Examine airfoil root, area a for nicks, dents or pits. One area of damage 0.005 inch (0.13 mm) deep is acceptable. |
| (17) | Airfoil trailing edge, area g:
NOTE: Area g extends 0.100 inch (2.54 mm) from airfoil trailing edge.
|
| (20) | Examine for erosion. Erosion of coating without exposure of base material is acceptable. |
| (21) | Examine blade platform for cracking. Non-converging cracks are acceptable if they do not enter area a of blade airfoil. |
| (22) | Examine blade platform for oxidation. Oxidation without material loss of the TE corners is acceptable. |
| (23) | Examine for blocked cooling holes. Clear as necessary. |
| (24) | If blades fail inspection, and must be replaced, or tips machined, send disk assembly to an overhaul facility. |
| (1) | Nicks, dents, scratches, scores, and corrosion pitting are acceptable to 0.005 inch (0.138 mm) deep on disk side face except for area located within 0.030 of fir tree fixings, and disk bore where 0.003 inch (0.08 mm) is acceptable. Remove sharp edges. Polish to restore surface finish. |
| (2) | Examine for indications of hot gas ingestion or overtemperature at the apex of fir tree fixings. White color indicates overtemperature. Send HPT disk assy to an overhaul facility if evident. |
| (1) | If blades are not within the following acceptance criteria, send disk assembly to an overhaul facility. |
| (2) | Examine area j: Oxidation with material loss is acceptable if the tip clearance and runout is within limits. |
| (3) | Examine area f: Erosion with complete coating removal is acceptable if within 0.050 inch (1.27 mm) of blade tip and wall thickness is more than 0.010 inch (0.25 mm). |
| (4) | Examine airfoil leading edge tip for nicks, burrs and raised material. Remove sharp edges. |
| (5) | Examine area d:
NOTE: Area d extends 0.100 inch (2.54 mm) from airfoil LE.
|
| (8) | Examine area b for nicks, dents and pits. Three areas of damage 0.003 inch (0.076 mm) deep are acceptable. |
| (9) | Examine area e for nicks, dents and pits. A maximum of one area of damage 0.005 inch
(0.127 mm) deep is acceptable.
NOTE: Area e extends 0.100 inch (2.54 mm) from airfoil TE.
|
| (10) | Examine area c for nicks, dents or pits. One area of damage 0.005 inch (0.127 mm)
deep is acceptable.
NOTE: Area c extends 0.150 inch (3.81 mm) from platform surface.
|
| (1) | Examine for cracks. No cracks permitted. Reject cover if evident. |
| (2) | Nicks, dents, scratches, scores, and corrosion pitting are acceptable to 0.003 inch (0.08 mm) deep. Remove sharp edges. Polish to restore surface finish. |
| (3) | Examine for security of balance counterweights retaining rivets. Replace as necessary. |
| (1) |
Examine outer case for:
|
| (4) | Examine carbon sealing ring for cracks or deterioration. Reject if evident. |
| (5) | Examine dia. A for nicks, chips or scratches.
|
| (9) |
Check operation of seal in case. Movement should be smooth without sticking or binding.
NOTE: Carry out dimensional inspection if oil leaks are evident.
|
| (10) | Dimensionally check dia. A using a bore gage employing air gap principle or equivalent. Acceptable provided dimension does not exceed specified limits REF. NO. 1133. |
| (11) | Dimensionally check remainder of carbon seal REF. NO. 1134. |
| (1) | Examine for cracks. No cracks permitted, reject if evident. |
| (2) | Examine for nicks or dents on functional surfaces that contact seal rings, diameters A, B and C, and shroud segment attachment rails. Acceptable to a maximum depth of 0.005 inch (0.13 mm), provided damage is removed by blending to a maximum depth of 0.007 inch (0.18 mm). |
| (3) | Examine for wear or fretting of Dia. A, Dia. B and or Dia. C. Acceptable to a maximum depth of 0.002 inch (0.05 mm). |
| (4) | Examine for blocked cooling holes. Clear as necessary. |
| (1) | Examine for cracks. Three cracks to a maximum length of 0.200 inch (5.080 mm) are acceptable if cracks are separated by a minimum of 0.300 inch (7.620 mm) and are non-converging. No cracks permitted in area a. |
| (2) | Examine for nicks. Any number acceptable to a maximum depth of 0.008 inch (0.203 mm) provided damage is removed by blending to a maximum depth of 0.010 inch (0.254 mm). |
| (3) | Examine for dents. Acceptable to a maximum depth of 0.010 inch (0.254 mm). |
| (4) | Examine for blocked cooling holes. Clear as necessary. |
| (5) | Examine for looseness. Send assembly to an overhaul facility if the baffle is loose. |
| (1) | Examine for cracks, distortion. Reject if evident. |
| (2) | Examine for fretting. Fretting is acceptable to a maximum of 0.005 inch (0.25 mm) deep. |
| (3) | Dimensionally check Dim. a, free state gap. If necessary cold rework the ring to obtain a minimum gap of 0.170 inch, do not exceed 0.225 inch. |
| (1) | Examine for cracks or distortion. Reject if evident. |
| (2) | Examine for radial clearance when installed in HPT housing with the gap at the top
as follows:
|
| (7) | Examine for evidence of damage, fretting or wear on faces. Acceptable to a maximum depth of 0.010 inch (0.013 mm). Stone to remove sharp edges and raised material |
| (1) | If the limits are exceeded, reject vane segments. Retain segments for future evaluation and possible repair. |
| (2) | Examine airfoil leading edge (LE):
|
| (5) | Examine airfoil trailing edge (TE):
|
| (14) | Examine airfoil surfaces:
|
| (21) | Examine inner and outer shroud TE lips:
|
| (28) | Examine Inner and Outer Shroud Gas Path - Surfaces
|
| (33) | Examine Inner and Outer Shroud Surfaces
|
| (36) | Examine Inner and Outer-Shroud Feather-seal Faces
|
| (39) | Examine Outer-Shroud Leading Edge
|
| (43) | Examine Cooling Holes, Inserts and Trailing-Edge Slots
|
| (45) | Examine Gas Path Surfaces
|
| (47) | Examine All Other Surfaces
|
| (1) | Outer shroud:
|
| (6) | Inner shroud:
|
| (11) | Vane leading edge:
|
| (16) | Check airfoil trailing edge as follows:
|
| (20) | Check airfoil pressure and suction surfaces as follows:
|
| (24) | Check inner and outer location lugs for evidence of wear, cracks or missing lugs. Lugs may be repaired. |
| (25) | Check sealing cap welds for evidence of cracking. Cracks are not acceptable. |
| (26) | Check airfoil and inner platform cooling holes for:
|
| (28) | Check all other surfaces for:
|
| (31) | Check for deterioration of surface treatment. Send assembly to an overhaul shop for restoration of surface treatment. |
| (32) | Check baffle for:
|
| (36) |
Examine brush seal for distortion, excessive wear, looseness and oil/carbon contamination
(Ref. Fig. ). The following conditions are acceptable:
|
| (1) | Inner and Outer shroud gas path surfaces:
|
| (10) | Airfoil leading edge:
|
| (15) | Airfoil trailing edge:
|
| (23) | Airfoil concave and convex surfaces:
|
| (30) | Check inner and outer location lugs for evidence of wear, cracks or missing lugs. Lugs may be repaired. |
| (31) | Check sealing cap welds for evidence of cracking. Cracks are not acceptable. |
| (32) | Check airfoil and inner platform cooling holes for:
|
| (34) | Check all other surfaces for:
|
| (37) | Check for deterioration of surface treatment. Send assembly to an overhaul shop for restoration of surface treatment. |
| (38) | Check baffle for:
|
| (42) | Examine brush seal for distortion, excessive wear, looseness and oil/carbon contamination. Clean or replace as required. |
| (1) | Examine sealing ring groove, dimension A. Fretting wear is acceptable if dimension A is less than 0.168 inch (4.27 mm). |
| (2) | Examine cooling holes for obstructions. Clear holes as necessary. |
| (3) | Any number of minor cracks and oxidation associated with the cooling holes at the leading edge chamfer are acceptable. |
| (4) | Area C:
|
| (9) | Inspect anti-rotation lugs (Pre-SB25156):
|
| (12) | Inspect anti-rotation lugs (Post-SB25156):
|
| (15) | Examine piston ring anti-rotation pin for wear. Check pin OD. If less than 0.096 inch (2.44 mm), replace shroud. |
| (16) | Examine all other surfaces:
|
| (1) | Examine diameter A for seal rub. Damage 0.007 inch (0.18 mm) deep and 0.010 inch (0.25 mm) wide is acceptable. Reject if limits are exceeded. Check dimension (Ref. Fits and Clearances, REF NO 1375) |
| (2) | Examine all other surfaces for nicks, dents, and/or fretting:
|
| (5) | Examine anti-rotation lugs for fretting. Minor fretting is acceptable if the step is removed. |
| (6) | Multiple radial hairline cracks on Dia. B and Face C (Area F) are acceptable providing the cracks do not extend into Dia. D. |
| (7) | Heavy oxidation with missing material at Dia. B and Face C is acceptable providing a minimum band of 0.100 inch contact surface remains undamaged (Ref. Fig. ). |
| (1) | Examine anchor nuts for attachment. Tighten or replace as necessary (Ref. Chapter 70-00-00, REPAIR). |
| (2) | Examine support for distortion. Reject support if bent or distorted. |
| (3) | Examine all other surfaces:
|
| (1) | Examine for cracks. Axial cracks that may be open and associated with local heavy oxidation at the outer ring of the segment locating groove are acceptable if they do not extend past the groove. |
| (2) | Examine for nicks or dents. Maximum combination of 10 is acceptable to 0.005 inch (0.13 mm) deep is acceptable. Damage 0.005 to 0.010 inch (0.13-0.25 mm) deep can be removed by blending to a maximum depth of 0.012 inch (0.30 mm). |
| (3) | Local heavy oxidation and/or burnt material and/or fretting of the segment locating
groove is acceptable if:
|
| (6) | Examine for loose, worn or damaged honeycomb turbine air seal. Reject if loose or
damaged.
NOTE: Replace the honeycomb and/or the first-stage high pressure turbine front cover labyrinth
seal if they are badly rubbed.
|
| (1) | Perform the special assembly procedure (REF. NO. 1825, 1826, 1827 and 1828), if the first-stage high pressure turbine front cover air nozzle assembly or honeycomb were replaced. |
| (1) | Examine for nicks or dents. Maximum combination of 10 is acceptable to 0.005 inch (0.13 mm) deep is acceptable. Damage 0.005 to 0.010 inch (0.13-0.25 mm) deep can be removed by blending to a maximum depth of 0.012 inch (0.30 mm). |
| (2) | Examine for loose, worn or damaged honeycomb turbine air seal. Reject if loose or
damaged.
NOTE: Replace the honeycomb and/or the first-stage high pressure turbine front cover labyrinth
seal if they are badly rubbed.
|
| (1) | Perform the special assembly procedure (REF. NO. 1825, 1826, 1827 and 1828), if the first-stage high pressure turbine front cover, air nozzle assembly or honeycomb were replaced. |
| (1) | Examine for cracks. Axial cracks that may be open and associated with local heavy oxidation at the outer ring of the segment locating groove are acceptable if they do not extend past the groove. |
| (2) | Examine for nicks or dents. Maximum combination of 10 is acceptable to 0.005 inch (0.13 mm) deep is acceptable. Damage 0.005 to 0.010 inch (0.13-0.25 mm) deep can be removed by blending to a maximum depth of 0.012 inch (0.30 mm). |
| (3) | Local heavy oxidation and/or burnt material and/or fretting of the segment locating
groove is acceptable if:
|
| (1) | Visually examine for cracks or deformation. Reject if evident. |
| (1) | Inspect for cracks. No cracks are permitted. |
| (2) | Inspect the carbon seal diameter. Surface damage, local and isolated pits, circumferential and axial scratch up to 0.003 in. (0.07 mm) maximum are serviceable. Reject the part if you find flaking or crack in the coating. |
| (3) | Reject the part if knife edge seals are damaged. Rubbing is serviceable. |
| (4) | Inspect brush seal diameter. Surface damage, local and isolated pits, circumferential and axial scratch up to 0.003 in. (0.07 mm) maximum are serviceable. Reject the part if you find flaking or crack in the coating. |
| (5) | Inspect all other surfaces for nicks and dents. Local surface damage up to 0.005 in. (0.12 mm) deep maximum is serviceable. Remove only raise material. |
| (6) | Make sure that the air seal damper is still in place and not damaged or broken. |
| (1) | Cracks: No cracks permitted. |
| (2) | Nicks and/or dents: Acceptable to a maximum depth of 0.007 inch (0.18 mm) if damage is removed by blending to a maximum depth of 0.010 inch (0.25 mm). |
| (3) | Examine rear inner and rear outer cover attachment rivets. Replace rivets if loose or damaged. |
| (1) | Examine area b for:
|
| (7) | Examine feather seal slots for:
|
| (10) | Examine all other surfaces for:
|
| (1) | Examine area(s) b for:
|
| (7) | Examine area c for:
|
| (9) | Examine feather seal slots for:
|
| (12) | Examine all other surfaces for:
|
| Tool No. | Name | Application |
|---|---|---|
| PWC37807 | Pump |
|
| PWC40700 | Adapter |
|
| PWC40781 | Adapter, Dyno-Torque Wrench | Replaces PWC41150 |
| PWC41050 | Wrench |
|
| PWC43265 | Socket |
|
| PWC43266 | Adapter |
|
| PWC43270 | Puller |
|
| PWC43271 | Pusher |
|
| PWC43272 | Puller |
|
| PWC43274 | Pad |
|
| PWC60761 | Sling |
|
| PWC60765 | Puller |
|
| PWC60766 | Puller |
|
| PWC60875 | Support |
|
| PWC61006 | Heater |
|
| PWC64241-6 | Pin, Alignment | Alternate to PWC66686-2 |
| PWC66686-2 | Pin | Obsolete - replaced by PWC64241-6 |
| PWC67176 | Heater Controller |
|
| PWC71392 | Adapter |
|
| PWC89837 | Cylinder |
| (1) | Remove retaining ring (1) and keywasher (2) . |
| (2) | Remove LP shaft rear plug (3) using puller (PWC43263) or (PWC60765). |
| (3) | Remove and discard preformed packings (4) . |
| (4) | Soak No. 4 bearing retaining nut (5) with a 50/50 mixture of engine oil (PWC03-001) and fuel (PWC01-001). |
| (5) | Install adapter (PWC43266) into slots at end of LP shaft. |
| (6) | Slide socket (PWC43265) over adapter and engage lugs with slots in No. 4 bearing retaining nut (5). |
| (7) | Install adapter (PWC40781) on power wrench (PWC41050). |
| (8) | Install power wrench on adapter and socket and remove No. 4 bearing retaining nut. |
| (9) | Loosen jaws of puller (PWC43267) and locate on front face of No. 4 bearing inner race (7) . Secure jaws in place. Turn center bolt of puller to position pad on LP shaft. |
| (10) | Remove No. 4 bearing (7) and No. 4 bearing Retaining ring (6) r together using puller PWC43267). Put bearing in a suitable clean container. |
| (11) | Remove flanged sleeve spacer (8) using puller (PWC60766). |
| (12) | Remove No. 4 bearing air seal (9) using puller (PWC43270). |
| (1) | Remove flange nuts. |
| (2) | Install LP compressor shaft pad (PWC43274) (1) into the LP shaft (2) . |
| (3) | Install puller (PWC43272) (3), adapter (PWC71392) (4), hydraulic cylinder (PWC89837) (5) and hydraulic pump (PWC37807) (6). |
| (4) | Install the sling (8) (PWC60761). |
| (5) | Apply pressure with the hydraulic pump (PWC37807) (6) to release the LPT module (7) . |
| (6) | Remove LPT module and place on holder (PWC43013). |
| (7) | Put protector (PWC61765) on LP shaft. |
| (1) |
Install LPT sling (PWC60761) (1).
NOTE: Make sure the lifting eye of the sling is at the top.
|
| (2) | Check dimension A as follows (Ref. Sheet 2):
|
| (6) | If necessary use bolt (2) and clamp (3) to obtain desired setting. |
| (7) | Once dim. A is set, lock rotor in position by tightening bolts (2) and knurled nut on clamp (3) hand tight. |
| (8) | Install guide pin (PWC66686-2) or (PWC64241-6) (4) at top on the LPT rotor case. |
| (9) | Make sure seal rings (5) are installed and joints are staggered 180° apart. Apply sealant (PWC08-014) sparingly to the rings to hold in a compressed and central position. |
| (10) |
Connect the heater (PWC61006) to the TOOL output on the controller (PWC67176).
NOTE: The indicated temperature is equivalent to 300° to 310°F (148.9 to 154.4°C) at the
front and rear spigot.
|
| (11) | Install heater into rotor bore. |
| (12) | Turn the main power switch to ON. |
| (13) | Check that controller is set for 490° to 500°F (254.4 to 260°C). |
| (14) | Set the timer to 7 minutes. |
| (15) | Start heating by pressing the HEATER START button. |
| (16) | Start the timer using the START/RESET switch. |
| (17) | Remove heater from rotor. |
| (18) | Install LPT assembly onto fan shaft, aligning splines and guide pin. |
| (19) | Install LPT assembly on LP shaft. |
| (20) | Install adapter (PWC40700) (6), drift (PWC43271) (7), cylinder (PWC89837) (8), and pump (PWC37807) (9). |
| (21) | Make sure adapter is fully threaded on the LP shaft. Apply 2150 to 2250 psi (14,823.7-15,513.2 kPa) pressure. Make sure LPT assembly goes on smoothly. |
| (22) | Release pressure. Unlock bolts (2) and clamps (3) out of position. Re-apply 2150 to 2250 psi (14,823.7-15,513.2 kPa) pressure. Maintain pressure until rotor and shaft temperatures equalize to room temperature. |
| (23) | Remove tools. |
| (24) | Install 4 brackets (1, Fig. ) with 1 bolt (5) and 3 bolts (6). |
| (25) | Install bracket (2) with bolt (6). |
| (26) | Install bracket (3) with bolt (6). |
| (27) | Install bracket (4) with 2 bolts (5). |
| (28) | Install 25 remaining bolts (6). |
| (29) | Tighten all 31 bolts in a star pattern 85 to 95 lb.in. (9.6-10.7 Nm). |
| (30) | Re-tighten until no movement is observed. |
| (31) | Make sure flange is completely seated. |
| (1) | Pre-SB25337:
|
| (10) | Post-SB25337:
|
| (1) | Pre-SB25337: Install four brackets (1) with four bolts (2) . |
| (2) | Post-SB25337: Install four brackets (1) with four bolts (2) and four nuts (12) . |
| (3) | Secure
transducer (3)
to bracket (4) (PWC43443) with 3
capscrews (5)
. Torque screws 13 to 15 lb. in. (1.5-1.7 Nm) and lockwire.
NOTE: Make sure pick-up and bracket mating surfaces are clean and free of burrs or raised
material.
|
| (4) | Pre-SB25337:
|
| (12) | Post-SB25337:
|
| (1) | Heat No. 4 bearing air seal (9) in oven at 204°C (400°F) for a 10 to 15 minutes. |
| (2) | Install No. 4 bearing air seal (9) with adapter (PWC40700), pusher (PWC43271), cylinder (PWC89837), and pump (PWC37807). Maximum cylinder pressure 950 to 1050 PSI. Maintain cylinder pressure until temperatures equalize. Remove tooling. |
| (3) | Heat No. 4 bearing sleeve spacer (8) in oven at 204°C (400°F) for a minimum of 15 minutes. |
| (4) | Install sleeve spacer (8) with cylinder (PWC89837), pump (PWC37807), adapter (PWC40700) and pusher (PWC43271). Maintain cylinder pressure until temperatures equalize. Remove tooling. |
| (5) | Make sure that you can see all No. 4 bearing oil lubrication holes on the LP shaft. |
| (6) | Heat the No. 4 bearing (7) in an oven pre-heated at 176 to 204°C (350 - 400°F) for 15 minutes minimum. |
| (7) | Remove the No. 4 bearing (7) from oven. |
| (8) | Install No. 4 bearing (7) with cylinder (PWC89837), pump (PWC37807), adapter (PWC40700) and pusher (PWC43271). Pressurize cylinder 950 to 1050 psi (6550 to 7239 kPa). Maintain cylinder pressure until temperatures equalize. Remove tooling. |
| (9) | Heat fuel shut off phonic ring (6) in oven at 204°C (400°F) for 10 to 15 minutes. |
| (10) | Install phonic ring (6) with cylinder (PWC89837), pump (PWC37807) and adapter (PWC40700) and pusher (PWC43271). Pressurize cylinder 950 to 1050 PSI. |
| (11) | Maintain cylinder pressure and allow low compressor shaft to cool to room temperature. |
| (12) | Remove tooling from LP shaft. |
| (13) | Lubricate threads on low compressor shaft and retaining nut (5) with engine oil (PWC03-001). |
| (14) | Install retaining nut (5) and torque (Fits and Clearances, REF. NO. 1706) using adapter (PWC43266), socket (PWC43265), adapter (PWC40781), wrench (PWC41050). |
| (15) | Fit plug (3) in LP compressor shaft, without packings, to determine the correct locking position of key washer (2). Fit keywasher (2). Mark locking position on key washer, plug and nut using an approved marker. Remove keywasher and plug. |
| (16) | Lubricate and install two new preformed packings (4) on plug (3). |
| (17) | Install plug (3) in low compressor shaft with drift (PWC60764). |
| (18) | Install keywasher (2) and retaining ring (1). |
| (1) | Examine for cracks. Reject if evident. |
| (2) | Examine for nicks or dents. Acceptable, with blending, to a maximum depth of 0.030 inch (0.8 mm). |
| (3) | Examine for evidence of isolated heat spots. Reject if evident. |
| (4) | Examine front and rear flanges for deformation. Reject if evident. |
| (5) | Examine clinch nuts for thread damage. Replace as necessary (Ref. 70-00-00, REPAIR). |
| (1) | Vane and/or blade deterioration is acceptable for continued service if component integrity is not effected, ie. no missing material, excessive damage, or airfoil distortion, and engine performance is within limits. |
| (1) | Examine for cracks. Reject if evident. |
| (2) | Examine for nicks or dents. Reject if evident. |
| (3) | Examine for evidence of damage to internal spline as follows:
|
| (8) | Examine for fretting on Faces A and/or B. Light fretting is acceptable. Remove raised metal and/or sharp edges. |
| (1) | Inspect for cracks. Reject assembly if evident. |
| (2) | Inspect for nicks or dents. Reject assembly if evident. |
| (3) | Inspect for cracked or deformed blade retaining rivets. Reject assembly if evident. |
| (1) | Vane and/or blade deterioration is acceptable for continued service if component integrity is not effected, ie. no missing material, excessive damage, or airfoil distortion, and engine performance is within limits. |
| (1) | Examine contact surfaces, fourth-stage disk area A, spacer area B and bearing contact
area C:
|
| (7) | Examine splines:
|
| Tool No. | Name | Application |
|---|---|---|
| PWC32396 | Jackscrew | Exhaust Case |
| PWC37807 | Hydraulic Pump | Exhaust Case |
| PWC40538 | Heater, Exhaust Case | Alternate to PWC61437 |
| PWC43580 | Puller | No. 4 Bearing Carbon Seal |
| PWC43581 | Drift | No. 4 Bearing Carbon Seal |
| PWC43582 | Base | No. 4 Bearing Carbon Seal |
| PWC43584 | Drift | Exhaust Case |
| PWC60134 | Puller | Exhaust Case |
| PWC60136 | Controller | Exhaust Case |
| PWC60927 | Lifter | Exhaust Case |
| PWC60995 | Gage | Fuel Shut-off Mechanism |
| PWC61437 | Heater, Exhaust Case | Obsolete - replaced by PWC40538 |
| PWC63134 | Drift, Seal Carrier |
|
| PWC63135 | Puller, Seal Carrier |
|
| PWC63141 | Drift, No. 4 Bearing Carbon Seal |
|
| PWC63224 | Base, No. 4 Bearing Seal Carrier |
|
| PWC63410 | Drift, Carbon Seal Carrier |
|
| PWC69269 | Heat Gun |
|
| PWC89837 | Hydraulic Cylinder | Replaces PWC32506 |
| (1) | Mark top center position of exhaust case (1) with an approved marker. |
| (2) | Pre-SB25294:
|
| (12) | Post-SB25294:
|
| (23) | Install lifter (PWC60927) and separate exhaust case with four jacking screws (PWC32396-100) on flange F at location L. |
| (24) | Remove exhaust duct assembly and place on a clean working surface. |
| (25) | Remove lifter and jacking screws. |
| (1) | Index mark seal carrier assembly (6) to exhaust case (1) with an approved marker. |
| (2) | Remove retaining ring (5) . |
| (3) | Pre-SB25273: Install cylinder (10) (PWC89837) and puller (PWC60134). |
| (4) | Post-SB25273: Install cylinder (10) (PWC89837) and puller (9) (PWC63135). |
| (5) | Connect pump (11) (PWC37807) to cylinder and remove seal carrier (6). |
| (6) | Remove retaining ring (4) and No. 4 bearing outer race (3) . Remove and discard sealing rings (2) . |
| (7) | Remove oil nozzle (7) and withdraw oil strainer element (8) . |
| (1) | Mount seal carrier assembly (1) on base (PWC43582). |
| (2) | Remove retaining ring (2) from seal carrier (1) . |
| (3) | Remove carbon seal (3) from seal carrier with puller (PWC43580). |
| (1) | Remove the retaining ring (2) from seal carrier (1). |
| (2) | Make three reference marks on the outside of the carrier in line with the center of the inner scallops and the three oil holes. |
| (3) | Put the seal carrier assembly in the base (part of PWC63410). Align the reference marks on the carrier with the three reference lines on the base (part of PWC63410). |
| (4) | Install drift (part of PWC63410) into position, turn the top of drift and install the cylinder (PWC89837). |
| (5) | Connect pump (PWC37807) (6) to cylinder (PWC89837) and remove carbon seal (3) from seal carrier (1). Discard the carbon seal (3). |
| (1) | Lubricate faces of No. 4 bearing carbon seal (3) with engine oil (PWC03-001), place in a plastic bag and put bag in freezer at -40°F (-40°C). |
| (2) | Place seal carrier (1) in oven at 400°F (204°C) for 15 minutes minimum. |
| (3) | Remove seal carrier (1) from oven and place in base (PWC43582). |
| (4) | Remove No. 4 bearing carbon seal (3) from freezer and install carbon seal (3) in seal carrier, serial number up, with drift (PWC43581). |
| (5) | Install retaining ring (2) . |
| (6) | Make sure that the carbon seal was not damaged during installation. |
| (1) | Lubricate the faces of No. 4 bearing carbon seal (3) with engine oil (PWC03-001), place in a plastic bag and put bag in freezer at -40°F (-40°C). |
| (2) | Place seal carrier (1) in oven at 400°F (204°C) for 15 minutes minimum. |
| (3) | Remove seal carrier (1) from oven and place in base (PWC63224). |
| (4) | Remove No. 4 bearing carbon seal (3) from freezer and install carbon seal (3) on the
drift (PWC63141) (5), seal against the upper flange of drift and serial number up with drift (PWC63141) (5).
NOTE: Freeze the seal and drift before the installation of seal on the drift.
|
| (5) | Install No. 4 carbon seal (3) in the carrier with the drift (PWC63141) (5) and base (PWC63224) (4). |
| (6) | Install retaining ring (2). |
| (7) | Make sure that the carbon seal was not damaged during installation. |
| (1) | Install strainer (8) in exhaust case. |
| (2) | Lubricate threads of oil nozzle (7) with engine oil (PWC03-001), install and torque 175 to 195 lbf.in. (19.8-22.0 Nm) (REF. NO. 1709, Fits and Clearances). |
| (3) | Lubricate two seal rings (2) with engine oil (PWC03-001)and install on No. 4 bearing outer race (3) . Make sure seal ring joints are staggered 180 degrees apart. |
| (4) | Lubricate No. 4 bearing outer race (3) with engine oil (PWC03-001)and install into turbine exhaust case (1) , with serial number facing upwards. Make sure anti-rotation lug on bearing engages with exhaust case. |
| (5) | Install retaining ring (4) . |
| (6) | Locally heat exhaust case bore for a minimum of 15 minutes with a heat gun. |
| (7) | Clean mating surfaces of carrier (6) and exhaust case (1) with cloth dampened in solvent (PWC11-014). |
| (8) | Pre-SB25273: Apply a thin coat of engine oil (PWC03-001) to seal. |
| (9) | Pre-SB25273: Apply a thin and even coat of locking and retaining compound (PWC09-002) around Area C of the seal carrier assembly (6) . |
| (10) | Post-SB25273: Do not use locking compound. Clean the mating surfaces again with a clean lint-free cloth soaked with solvent (PWC11-014) and allow to dry. |
| (11) | Heat exhaust case - Method A:
|
| (14) | Heat exhaust case - Method B:
|
| (18) | Pre-SB25273: When time is up remove heater and install carrier seal assembly (6) in exhaust case with drift (PWC43584). |
| (19) | Post-SB25273: When time is up remove heater and install carrier seal assembly (6) in exhaust case with drift (11) (PWC63134). |
| (20) | Pre-SB25273: Remove any excess traces of locking and retaining compound (PWC09-002). Make sure that no compound in contact with the carbon seal element. |
| (21) | Install retaining ring (5) . |
| (1) | Apply a thin film of anti-seize compound (PWC06-009) to threads of screws (2) . |
| (2) | Align holes and install exhaust cone (3) on exhaust case flange (4). |
| (3) | Install screws (2) and torque 18 to 22 lb.in. (2-2.4 Nm). |
| (1) | Remove cotterpin (12) , washer (11) , pin (10) and control rod (13) from lever (9) . Discard cotterpin. |
| (2) | Remove cotterpin (12), washer (11), pin (14) and control rod (13) from bellcrank (15) . Discard cotterpin. |
| (3) | Remove control rod (13) from exhaust case (1) through port in strut at bellcrank mounting bracket (16) . |
| (4) | If required, remove remaining overspeed control linkage:
CAUTION: IF OVERSPEED CONTROL PIN IS REMOVED FOR ANY REASON, RETAINING BLOCK MUST BE REMOVED
THEN REINSTALLED AS PART OF OVERSPEED CONTROL PIN DIMENSIONING PROCEDURE (REF. PARA.
).
|
| (1) | If required, fasten bellcrank mounting bracket (16) to mounting bosses on exhaust case (1) with three bolts (20) . Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | If removed, install bellcrank (15) to bracket (16) with bolt (17) and nut (18) . Torque nut 65 to 85 lb.in. (7.3-9.6 Nm) and install cotterpin (19) . |
| (3) | Check pin clearance (REF. NO. 1282, Table 601) as follows:
|
| (11) | Install serviceable ring seal (6) in overspeed linkage pin bore. |
| (12) | Install pin (8) into retaining block (3). Install retaining block and two
bolts (7)
. Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm).
NOTE: Do not install retaining block in exhaust case before pin is installed in retaining
block.
|
| (13) | Install fork on lever (9) over head of pin (8). |
| (14) | Fasten lever (9) to retaining block with sleeve spacer (4) , bolt (5) and nut (2) . Torque nut to 36 to 40 lb.in. (4.1-4.5 Nm). |
| (15) | Insert control rod (13) through exhaust case port at bellcrank mounting bracket (16). |
| (16) | Fasten control rod (13) to lever (9) with pin (10) , washer (11) and cotterpin (12) . |
| (17) | Fasten control rod (13) to bellcrank (15) with pin (14) , washer (11) and cotterpin (12). |
| (18) | Adjust bolt (7) to obtain lever locating dimension (Fits and Clearances REF. NO. 1281) and fasten with nut (6). Torque nut (6) 75 to 85 lb.in. (8.5-9.6 Nm) and install lockwire (PWC05-089). |
| (19) | Check pin and linkage installation:
|
| (1) | Install lifter (PWC60927). |
| (2) | Lubricate faces of No. 4 bearing carbon seal with engine oil (PWC03-001). |
| (3) | Align top center mark of exhaust case (1) with mark on flange F of LP turbine assembly. Align flange locating pin and install exhaust case. |
| (4) | Pre-SB25294:
|
| (16) | Post-SB25294:
|
| (29) | Torque all nuts (2) 85 to 95 lb.in. (9.6-10.7 Nm) in a star pattern. |
| (30) | Remove lifter, and install engine mounts (Ref. Aircraft Maintenance Manual). |
| (1) | Inspect for cracks. Cracks are acceptable within the following limits:
|
| (6) | Visually inspect No. 4 bearing external pressure and scavenge oil tubes for cracks and corrosion. Reject exhaust case if any cracks or corrosion is found. |
| (7) | Nicks and dents are acceptable to a maximum depth of 0.030 inch (0.76 mm). |
| (8) | Reject exhaust case if any corrosion, isolated heat spots or deformed flanges are found. |
| (1) | Inspect for cracks in welded seams as follows:
|
| (4) | If cracks are found in other areas, reject exhaust case. |
| (5) | Nicks and dents are acceptable to a maximum depth of 0.015 inch (0.38 mm). |
| (6) | If isolated heat spots are found, reject component. |
| (1) | Check nozzle and strainer for damage or blockage. Reject if any damage is found. |
| (1) | Examine outer case for:
|
| (4) | Examine carbon sealing ring for cracks or deterioration. Reject if evident. |
| (5) | Examine dia. A for nicks, chips or scratches. Acceptable up to a maximum of 0.005 inch deep provided a continuous band at least 50 percent of original seal width remains undamaged. |
| (6) | Examine side faces and chamfers. Nicks, chips and scratches are acceptable provided the sealing in the housing is not affected. |
| (7) |
Check operation of seal in case. Movement should be smooth without sticking or binding.
NOTE: Carry out dimensional inspection if oil leaks are evident.
|
| (8) | Dimensionally check Dia. A using a bore gage employing air gap principle or equivalent. Acceptable provided dimension does not exceed specified limits (F & C REF. NO. 1175). |
| (9) | Dimensionally check remainder of carbon seal (F & C REF. NO. 1176). |
| (1) | Inspect complete fuel shut-off mechanism for freedom of movement and correct operation. Particular attention must be directed to the No. 4 bearing housing shut-off pin, exhaust case connecting rod and shut-off cable to ensure operation without interference or contaminate build up. |
| (2) | Remove the exhaust cone. |
| (3) | Check the operation of the pin by moving the control rod up maximum deflection. |
| (4) | Check for cracks. Reject if found. |
| (5) | Nicks and dents are acceptable to a maximum depth of 0.005 inch (0.13 mm). |
| Tool No. | Name | Application |
|---|---|---|
| PWC43176 | Puller |
|
| PWC43177 | Puller |
|
| PW58104 | Wrench Assembly Connector |
|
| PWC60144 | Adapter |
|
| PWC60225-01 | Drift |
|
| PWC60635 | Puller |
|
| PWC60679 | Extractor |
|
| PWC60682 | Pusher |
|
| PWC60683 | Pusher |
|
| PWC60684 | Extractor |
|
| PWC60685 | Pusher |
|
| PWC61155 | Drift |
|
| PWC61951 | Puller |
|
| PWC66103 | Puller |
|
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Remove breather tube (Ref. Aircraft Maintenance Manual). |
| (2) | Remove two bolts (10) and two washers (9) securing the breather adapter (8) to the accessory gearbox. |
| (3) | Remove breather adapter (8) from the AGB using puller (PWC43177). |
| (4) | Remove and discard preformed packing (7) from the breather adapter. |
| (5) | Remove retaining ring (6) . |
| (6) | Remove lip seal (5) using extractor (PWC43176). |
| (1) | Remove any raised material from the breather adapter retaining ring groove. |
| (2) | Heat the breather adapter (8) in oven at 300°F to 350°F (148°C to 176°C) for 15 to 20 minutes. |
| (3) | Remove the breather adapter from the oven. |
| (4) | Lightly lubricate the inner surface of the adapter with assembly fluid mixture (50% engine oil (PWC03-001) and 50% assembly fluid PWC06-011). |
| (5) | Lightly lubricate the outer surface of lip seal (5) with assembly fluid mixture (50% engine oil (PWC03-001) and 50% assembly fluid PWC06-011). |
| (6) |
Seat the lip seal into the breather adapter using drift (PWC60225-01).
NOTE: Do not remove the mandrel from the lip seal.
|
| (7) | Install retaining ring (6) in the groove inside the breather adapter. |
| (8) | Lubricate preformed packing (7) with engine oil (PWC03-001) and install on breather adapter (8). |
| (9) | Clean the breather gearshaft in the area of the lip seal running surface and dry using
alcohol (PWC11-014).
NOTE: A clean and dry gearshaft will result in better seating of the lip seal to the shaft
during initial engine run.
|
| (10) | With the mandrel still fitted in the lip seal, align the mandrel with the breather
shaft and push the adapter in place by hand.
NOTE: The shaft will push the mandrel out from the adapter.
|
| (11) | Discard the mandrel. |
| (12) | Lubricate the threads of two bolts with engine oil (PWC03-001) and secure the breather adapter (8) to the accessory gearbox with two washers (9) and two bolts (10) . Torque the bolts 36 to 40 lb.in. (4.1-4.6 Nm.). |
| (13) | Install the breather tube (Ref. Aircraft Maintenance Manual). |
| (1) | Gain access to hydraulic pump lip seal by removing hydraulic pump (Ref. Aircraft Maintenance Manual). |
| (2) | Remove retaining ring (14) . |
| (3) | If necessary, cut the Teflon seal (13) with suitable knife to install the extractor. |
| (4) | Remove seal (13) with the extractor (PWC60684). |
| (1) | Remove any raised material from the hydraulic pump retaining ring groove. |
| (2) | Clean the hydraulic pump gearshaft in the area of the lip seal contact and dry with
alcohol (PWC11-014).
NOTE: A clean and dry gearshaft will result in better seating of the lip seal during initial
engine run.
|
| (3) | Lightly lubricate the outer surface of lip seal (13) with assembly fluid mixture (50% engine oil (PWC03-001) and 50% assembly fluid PWC06-011). |
| (4) | With the mandrel fitted in seal (13), align the mandrel to the shaft and push the seal squarely onto the hydraulic pump shaft. |
| (5) | Remove and discard the mandrel. |
| (6) | Install the lip seal with the pusher (PWC60683). Torque the pusher from 50 to 60 lb.in. (5.8 - 6.9 Nm.). |
| (7) | Install retaining ring (14) . |
| (8) | Install hydraulic pump (Ref. Aircraft Maintenance Manual). |
| (1) | Remove the hydraulic pump (Ref. Aircraft Maintenance Manual). |
| (2) | Remove hydraulic pump gearshaft lip seal (Ref. Para. , above). |
| (3) | Remove retaining ring (12) . |
| (4) | Remove hydraulic pump gearshaft
splined adapter (11)
using puller (PWC60635).
NOTE: Store splined adapter with hydraulic pump gearshaft parts to avoid mixing with other
AGB splined adapters.
|
| (1) | Lubricate the internal splines of the hydraulic pump gearshaft with engine oil (PWC03-001). |
| (2) | Install
splined adapter (11)
into the gearshaft by lightly tapping with a soft faced drift (PWC61155).
NOTE: Fully seat splined adapter to allow installation of the retaining ring.
|
| (3) | Install retaining ring (12) . |
| (4) | Install the hydraulic pump gearshaft lip seal (Ref. Para. , above). |
| (5) | Install the hydraulic pump (Ref. Aircraft Maintenance Manual). |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Remove HMU (Ref. Chapter 73-20-01, HYDROMECHANICAL METERING UNIT - MAINTENANCE PRACTICES). |
| (3) | Disconnect wiring harness connectors P11 and P12 from PMA/AC generator housing connectors (13 and 12). |
| (4) | Remove five self-locking nuts (10) and washers (9) securing PMA/AC generator housing (8) to AGB cover. |
| (5) | Remove housing (8). Discard preformed packing (7) . |
| (6) | Remove retaining ring (6) and keywasher (5) . |
| (7) | Remove retaining nut (4) using socket (PWC43553) and adapter (PWC60144). |
| (8) | Remove rotor (3) from fuel pump gearshaft (2) . |
| (1) | Install PMA/AC generator rotor (3) on fuel pump gearshaft (2) . |
| (2) | Lubricate threads and mating face of retaining nut (4) with engine oil (PWC03-001) and install on fuel pump gearshaft (2). |
| (3) | Torque 600 to 800 lb.in. (69.4 to 92.4 Nm.) using socket (PWC43553) and adapter (PWC60144). |
| (4) | Loosen nut to zero. |
| (5) | Retorque to 600 lb.in. (69.4 Nm.). |
| (6) | Tighten to the next locking position. |
| (7) | Install keywasher (5) and retaining ring (6) on retaining nut (4). |
| (8) | Install new preformed packing (7) on PMA/AC generator housing (8) . |
| (9) | Install housing (8) over rotor (3).
NOTE: Set locating pin (11) at the 6 o'clock position.
|
| (10) | Secure housing (8) with five washers (9) and five self-locking nuts (10) . Torque 32 to 36 lb.in. (3.6-4.1 Nm.). |
| (11) |
Attach wiring harness connector P12 to housing connector (12) and harness connector
P11 to housing connector (13). Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL-JAWED
PLIERS TO TIGHTEN CONNECTORS.
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (14) | Restore electrical power to appropriate system and reset EEC circuit breaker to ON. |
| (15) | Select maintenance discrete OFF. |
| (16) | Refer to Chapter 71-00-00, POWER PLANT - ADJUSTMENT/TEST, for checks following installation of the PMA/AC generator. |
| (1) | Remove HMU (Ref. Chapter 73-20-01, HYDROMECHANICAL METERING UNIT - MAINTENANCE PRACTICES). |
| (2) | Remove retaining ring (15, Fig. , Sheets 1 and 2). |
| (3) | Remove PMA/AC generator housing from the AGB (Ref. Para. ). |
| (4) | Remove lip seal (16) by pushing outward from inside of the housing, using teflon drift (PWC51137). |
| (1) | Remove any raised material from the PMA/AC generator retaining ring groove. |
| (2) | Clean the gearshaft in the area of the lip seal contact surface and dry with alcohol
(PWC11-014).
NOTE: A clean and dry gearshaft will result in better seating of the lip seal during initial
engine run.
|
| (3) | Lightly lubricate the outer surface of lip seal (16) with assembly fluid mixture (50% engine oil (PWC03-001) and 50% assembly fluid PWC06-011). |
| (4) | With the mandrel fitted in the seal (16), align the mandrel to the shaft and push the seal squarely onto the shaft. |
| (5) | Remove and discard the mandrel. |
| (6) | Install the lip seal with the pusher (PWC60685). Torque the pusher from 50 to 60 lb.in. (5.8-6.9 Nm.). |
| (7) | Index the pusher 180 degrees and retorque 50 to 60 lb.in. (5.8-6.9 Nm.). |
| (8) | Install retaining ring (15) . |
| (9) | Install the PMA/AC generator housing onto the AGB (Ref. Subpara. ). |
| (1) | Remove alternator or starter to gain access to the lip seal (Ref. Aircraft Maintenance Manual). |
| (2) | Remove the starter shaft shield (22) using puller (PWC61951). Remove and discard preformed packing (21) . |
| (3) | Remove retaining ring (1) or (20) (Ref. Fig. , Section F-F, Section G-G similar). |
| (4) | If necessary, cut the Teflon seal (13) with suitable knife to install the extractor. |
| (5) | Remove lip seal (2) or (19) with the extractor (PWC60679). |
| (1) | Remove any raised material from the retaining ring groove. |
| (2) | Clean the gearshaft in the area of the lip seal contact and dry with alcohol (PWC11-014).
NOTE: A clean and dry gearshaft will result in better seating of the lip seal during initial
engine run.
|
| (3) | The new seal (2) or (19) is supplied pre-installed on mandrel. Make sure seal is fitted properly on mandrel. |
| (4) | Lightly lubricate the outer surface of lip seal with assembly fluid mixture (50% engine oil (PWC03-001) and 50% assembly fluid PWC06-011). |
| (5) | With the mandrel fitted on the seal, align the mandrel to the shaft and push the seal squarely onto the shaft. |
| (6) | Carefully remove the mandrel. |
| (7) | Install the lip seal onto the shaft with the pusher (PWC60682). Torque the pusher from 50 to 60 lb.in. (5.8-6.9 Nm.). |
| (8) | Index the pusher 180 degrees and retorque 50 to 60 lb.in. (5.8-6.9 Nm.). |
| (9) | Install the retaining ring (1) or (20) in the groove. |
| (10) | Install preformed packing (21) on the starter shaft shield (22) . |
| (11) | Install the starter shaft shield. |
| (12) | Install alternator or starter (Ref. Aircraft Maintenance Manual). |
| (1) | Remove alternator or starter (Ref. Aircraft Maintenance Manual). |
| (2) | Remove lip seal (Ref. Para. , above). |
| (3) | Remove retaining ring (3) or (18) . |
| (4) | Remove splined adapter
(4)
or
(17)
using puller (PWC60635).
NOTE: Store splined adapter with the alternator or starter gearshaft parts to avoid mixing
with other AGB splined adapters.
|
| (1) | Examine the starter splined adapter (17, Fig. ) for the following damage (Ref. Fig. , Section A-A, Area 1):
|
| (7) | Reject if damage is not within the specified limits. |
| (1) | Lubricate the internal splines of the alternator or starter gearshaft with engine oil (PWC03-001). |
| (2) | Install splined adapter
(4)
or
(17)
into the gearshaft by lightly tapping with a soft faced drift (PWC61155).
NOTE: Fully seat splined adapter to allow installation of the retaining ring.
|
| (3) | Install retaining ring (3) or (18) . |
| (4) | Install the alternator or starter gearshaft lip seal (Ref. Para. , above). |
| (5) | Install the alternator or starter (Ref. Aircraft Maintenance Manual). |
| (1) | Pre-SB25088:
|
| (4) | Post-SB25088:
|
| (1) | Pre-SB25088:
|
| (5) | Post-SB25088:
|
| (1) | Remove head of four rivets (3) using a 0.125 inch diameter drill. |
| (2) | Using a suitable punch, light tap the rivet stem through the trim plate (5) and identification plate (4) until the plate is free. |
| (3) | Remove four screws (2) and retaining plate (1) . |
| (4) | Remove wasted portion of rivets (3) from cavities in accessory gearbox housing. |
| (1) | Secure retaining plate (1) to AGB with four screws (2) . Torque screws 9 to 11 lb.in. (1.0-1.2 N.m). |
| (2) | Install identification plate (4) on retaining plate (1). Put trade mark on identification plate forward. Secure with two blind rivets (3) in the front corners using suitable riveting tool. |
| (3) | Install trim plate (5) over bottom portion of identification plate (4) and make sure no information is obscured. Secure with two blind rivets (3) using suitable tool. |
| (4) | Cut and file rivet stems flush to head. Do not push rivet stem inside AGB case. |
| (1) | Remove the starter-generator or alternator from the AGB (Ref. AMM). |
| (2) | A locally manufactured hole guide is recommended to get the required repair tolerances. |
| (3) | Drill mount pad hole to diameter of 0.515 to 0.521 in. and to depth of 0.750 in. |
| (4) | Make a chamfer of 82° to 100° with a diameter of 0.572 to 0.582 in. |
| (5) | Tap the hole: 0.5625-12 UNC-2B to 0.560 in. minimum, full depth threads. |
| (6) | Clean the area. |
| (7) | Apply the chromate conversion solution on the magnesium casings (Ref. 70-00-00, STANDARD PRACTICES - REPAIR). |
| (8) | Measure the wall thickness between the bottom of the hole and the back of the mount pad flange. Make sure it is 0.090 in. minimum. |
| (9) | Install a Keensert insert P/N MS51831A204L or MS51831A204 or any equivalent 0.010
to 0.030 in. below the surface of the hole.
NOTE: Other equivalent insert P/N's can also be used: NAS1395C6L, NAS1395-6L or KNH624J.
|
| (10) | Drive the insert locking keys down. |
| (11) | Install the starter-generator or alternator on the AGB (Ref. AMM). |
| (1) | Gain access to the outer fan duct (Refer to Aircraft Maintenance Manual). |
| (2) | Disconnect affected aircraft supplied drain fittings and all other related components (Refer to Aircraft Maintenance Manual). |
| (3) | Disconnect the rear engine mount link from the engine mount spar (Refer to Aircraft
Maintenance Manual).
NOTE: Rear engine mount links assembly is part of the rear outer bypass duct assembly
and is removed with the bypass duct.
|
| (4) | Remove two bolts and washers (Ref. View M-M) attaching bottom of rear outer bypass duct to the engine lower outer bypass duct flange. |
| (5) | Remove rear outer bypass duct attachment bolts, washers and nuts at positions where
electrical harness and engine equipment support brackets are located.
NOTE: Take note of the position and orientation of all brackets prior to removal.
|
| (6) | Position electrical harness and engine equipment support brackets as necessary to
clear rear outer bypass duct flange during removal.
NOTE: Engine supplied brackets are mounted on the rear side of the engine outer bypass
duct and the airframe supplied brackets are mounted on the front side of the rear
outer bypass duct.
|
| (7) | Support rear outer bypass duct and remove remaining bolts, washers and nuts attaching rear outer bypass duct to engine outer bypass duct. |
| (8) | Carefully remove the rear outer bypass duct. |
| (1) | Remove bolts (30) , washers (31) and access door (32) . |
| (2) | Post-SB25107 (Ref. Fig. ):
|
| (1) | Position rear outer bypass duct and align locating pins on the engine outer bypass duct flange. |
| (2) | Install bolts (3) , washers (2) , nuts (1) and fingertight at positions not attaching electrical harness or engine component support brackets (Ref. Section L-L). |
| (3) | Position electrical harness and install engine components support
brackets (4)
. Install bolts (3), washers (2), nuts (1), brackets (4) and tighten nuts with fingers.
NOTE: Position and orientation of the engine and airframe brackets must be the same as
when they were removed.
|
| (4) | Secure bottom of rear outer bypass duct to engine outer bypass duct flange with two bolts (3) (Ref. View M-M). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (5) | Torque all rear outer bypass duct attachment nuts to 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Install rear engine mount links to engine mounting lugs in the aircraft (Refer to Aircraft Maintenance Manual). |
| (1) | Install access door (32) with bolts (30) and washers (31) . |
| (2) | Torque bolts (30) 36 to 40 lb.in. (4.0-4.5 Nm). |
| (3) | Post-SB25107 (Ref. Fig. ):
|
| (1) | Remove ten nuts (16) , ten spacers (26) and two front heat shields (25) . |
| (2) | Support the engine resilient mount (23) and remove ten bolts (18) two rear heat shields (17) . |
| (3) | Remove engine resilient mount (23) together with two links (24) , two support brackets (28) and place them in a clean container. |
| (1) | Position engine resilient mount (23) together with the two links (24) , two support brackets (28) and install them on rear outer bypass duct. |
| (2) | Install two rear heat shields (17) on ten bolts (18) , install them on the support brackets (28) and the respective engine rear outer bypass duct mount. |
| (3) | Install front heat shields (25) , spacers (26) and nuts (16). |
| (4) | Torque nuts (16) 85 to 95 lb.in. (9.6-10.7 Nm). |
| (1) | Remove four cotter pins (9) and discard. |
| (2) | Remove four nuts (10) and bolts (15) , washers (14) and (11) and remove two links (24) form the resilient mount (23) and support brackets (28) . |
| (3) | Place links in suitable clean container. |
| (1) | Position links (24) on the resilient mount (23) and support brackets (28) . |
| (2) | Make sure four
flanged bushings (13)
and plain
bushings (12)
are installed on two links (24) and resilient mount (23).
NOTE: Flanged bushings are on fork end of resilient mount (23) and support brackets (28).
|
| (3) | Install four
bolts (15)
with chamfer
washers (14)
and install on flanged bushings (13).
NOTE: Chamfer washer towards bolt head.
|
| (4) | Install four washers (11) and nuts (10) . |
| (5) | Torque four nuts 225 to 300 lb.in. (25.4-33.9 Nm). |
| (6) | Install four new cotter pins (9) . |
| (1) | Using the proper allen wrench, hold
pin (20)
and remove
nut (21)
and
bracket (27)
or
plate (29)
.
NOTE: It is necessary to hold the pin (20) located at the top of the duct from inside
the duct. This is to prevent the pin from falling inside the engine.
|
| (2) | Depending on which side the engine is installed, install pin (20) with bracket (27) or plate (29). |
| (3) | Install nut (21). Torque nut 62 to 72 lb.in. (7.0-8.1 Nm). |
| (1) | Remove two bolts (8) lifting bracket (7) washers (6) and nuts (5) . |
| (2) | Do a dimensional inspection of resilient engine mount (Ref. Para. ). |
| (1) | Install two bolts (8) on
lifting bracket (7)
with two
washers (6)
and
nuts (5)
.
NOTE: Lifting bracket installed on rear flange.
|
| (2) | Torque nuts (5) 62 to72 lb.in. (7.0-8.1 Nm). |
| (1) | Location F. Remove bolt (3) . |
| (2) | Remove 22 bolts (8) and washers (2) from the side flange. |
| (3) | Location E. Remove bracket (7) , bolt (3), washer (4) and nut (5) . |
| (4) | Location D. Remove bracket (6) , bolt (3), washer (4) and nut (5). |
| (5) | Location C. Remove 4 bolts (3) and 4 washers (4). |
| (6) | Location B. Remove 3 bolts (3), washers (4). |
| (7) | Location A. Remove 12 bolts (3), 24 washers (4) and 12 nuts (5). |
| (8) | Remove the forward upper outer bypass duct (1) , at Flange C. |
| (1) | Apply a thin coat of grease (PWC09-003) to the mating face of Flange C on the duct (1) . |
| (2) | Install the forward upper bypass duct (1) . |
| (3) | Attach the duct (1) at Flange C:
|
| (9) | Attach the side flange with 22 bolts (8) and washers (2) . Torque 27 to 30 lbf.in. (3.0 - 3.3 Nm), dry. |
| (10) | At location F, install bolt (3). Tighten with your hand, oil. |
| (1) | Remove 18 bolts (8) , washers (25) and remove upper bypass duct fairings (9) and (11) . |
| (2) | Remove 26 bolts (2) , washers (25) and remove bypass duct segments (3) and (4) . |
| (3) | Remove six
bolts (5)
and remove fairing support brackets
(7)
and
(12)
.
NOTE: Fairings support brackets (7 and 12) may remain attached to the inner bypass ducts
segments (3 and 4) unless replacement is necessary.
|
| (1) | If necessary, install fairing support brackets (12) and (7) on inner left and right bypass duct segments (3 and 4) with six bolts (5) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (2) | Install inner bypass duct segment (3) . Make sure front edge is correctly inserted under flange (19) (Ref. Section A-A). |
| (3) | Install 11 bolts (2) and washers (25). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (4) | Install upper right bypass duct segment (4) . Make sure front edge is correctly inserted under flange (19) (Ref. Section A-A). |
| (5) | Install 15 bolts (2) and washers (25). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Loosely install fairing (9) and make sure that bracket (7) is properly aligned to provide support. Adjust bracket (7) as necessary to contact inside of fairing (9). |
| (7) | Attach upper right bypass duct fairing (9) with nine bolts (8) and washers (25). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Loosely install fairing (11) and make sure that bracket (12) is properly aligned to provide support. Adjust bracket (12) as necessary to contact inside of fairing (11). |
| (9) | Attach upper left bypass duct fairing (11) with nine bolts (8) and washers (25). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (1) | Disconnect front core wiring harness from lower fairings (4) and (15) (Ref. 73-20-03). |
| (2) | Remove five bolts (3) , washers (22) and remove lower left side fairing (15). |
| (3) | Remove four self locking nuts (18) , four washers (19) , two bolts (20) , two washers (22), two bolts (17) , two washers (22) and remove fairing (11) . |
| (4) | Remove ten bolts (3), washers (22) and remove fairings (12) and (10) . |
| (5) | Remove five bolts (3), washers (22) and remove fairing assemblies (4) and (5) . |
| (6) | Pre-SB25278: Remove two bolts (3), washers (22) and remove lower right top section (8) . |
| (7) | Post-SB25278: Remove three bolts (3), washers (22) and remove lower right top section (23) . |
| (8) | Remove two bolts (3), washers (22) and lower right bypass duct segment (21) . |
| (9) | Pre-SB25278: Remove 16 bolts (3) , washers (22) and blow off valve access cover (9) . |
| (10) | Post-SB25278: Remove 17 bolts (3) , washers (22) and blow off valve access cover (24) . |
| (11) | Remove two bolts (3) and remove fairing support bracket (7) . |
| (12) | Remove three bolts (3), washers (22) and remove fairing support bracket (14) . |
| (13) | Remove ten bolts (3), washers (22) and bypass duct segment (13) . |
| (1) | If necessary, install fairing support brackets (14) and (7) on lower duct segments (13) and (8) in the same position as marked during removal. Attach with five bolts (3) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (2) | Install lower bypass duct segment (13). Make sure front edge is correctly inserted under flange (16) (Ref. View A). |
| (3) | Install ten bolts (3). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (4) | Install lower right bypass duct segment (21) with two bolts (3) and washers (22) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (5) | Pre-SB25278: Install blow off valve access cover (9) . Make sure front edge is correctly inserted under flange (16) (Ref. View A). |
| (6) | Post-SB25278: Install blow off valve access cover (24) . Make sure front edge is correctly inserted under flange (16) (Ref. View A). |
| (7) | Pre-SB25278: Install 16 bolts (3) and 16 washers (22) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Post-SB25278: Install 17 bolts (3) and 17 washers (22) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (9) | Pre-SB25278: Install lower right top section (8) on duct segment (9) with two bolts (3) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (10) | Post-SB25278: Install lower right top section (23) on duct segment (24) using two bolts (3) and washers (22). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (11) | Assemble fairings (4) and (5) . Attach with two bolts (3) and washers (22). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (12) | Install fairing assembly (4 and 5) on bypass duct half (2). Attach with five bolts
(3) and washers (22). Torque 36 to 40 lb.in. (4.0-4.6 Nm).
NOTE: If required adjust fairing support (7) until it contacts fairing assembly (4 and
5).
|
| (13) | Install
fairing assembly (15)
on bypass duct half (2). Attach with five bolts (3) and washers (22). Torque 36
to 40 lb.in. (4.0-4.6 Nm).
NOTE: If required adjust fairing support (14) until it contacts fairing assembly (15).
|
| (14) | Install fairing assembly (10) with four bolts (3), washers (22). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (15) | Install fairing (12) with six bolts (3) and six washers (22). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (16) | Position lower rear fairing (11) on bypass duct half (2). Attach fairing with two bolts (17) , two bolts (20) , four washers (19) , four washers (22), and four self-locking nuts (18) . Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Remove any remaining original sealant from the fairing assemblies (3) with a suitable non-metallic scraper. |
| (2) | Clean area a adjacent to the gap with isopropyl alcohol (PWC11-014). |
| (3) | Apply sealant (PWC09-019) at area a to fill the gap all around the fairing assemblies (3). |
| (4) | If necessary, moisten finger with water and gently smooth out the sealant. |
| (1) | Inspect upper and lower outer by-pass duct upper and lower for:
|
| (8) | Inspect inner by-pass duct fairings for:
|
| (16) | Inspect BOV cover and remaining inner by-pass ducts for:
|
| (25) | Inspect Nut plates:
|
| (27) | Inspect rear outer by-pass duct:
NOTE: It is acceptable to operate engines with some or all of this filler missing.
|
| (1) | Cut the outer layers to obtain access to delaminated area. |
| (2) | Mix a two-part mix of high temperature sealant (PWC09-025) (Ref. Sealant Manufacturer's Instructions). |
| (3) | Inject sealant mixture (PWC09-025) into the delaminated areas. Spread into full area beneath delaminated layer. |
| (4) | Make sure space between layers is completely filled with sealant. |
| (5) | Apply light pressure to the layers with a suitable teflon or nylon scraper to evenly spread compound and remove the entrapped air. |
| (6) | Apply sealant mixture (PWC09-025) over the cut areas of the outer layers to seal the repair. |
| (7) | Remove any excess material from outer layer surface. |
| (8) | Cure the repair areas for 40 minutes or in accordance with sealant manufacturer's curing instructions. |
| (1) | Remove any loose material. |
| (2) | Thoroughly clean area with wire brush to remove any residual sealant and prepare for bonding. |
| (3) | Fill area b with sealant (PWC09-001A) (Ref. Standard Practices Manual). |
| (4) | Visually check condition of sealant and touch up holes as necessary. |
| • | Hydromechanical fuel control unit (HFCU or HMU). |
| • | Engine-driven, two-stage cartridge-style fuel pump mounted in the HMU. |
| • | Fuel filter. |
| • | Fuel/oil heat exchanger. |
| • | Start/dump valve. |
| • | Fuel waste ejector. |
| • | Fuel shutoff valve. |
| • | Fuel manifold containing 22 main fuel nozzles and 2 hybrid nozzles. |
| • | Motive flow valve. |
| Tool No. | Name | Application |
|---|---|---|
| PWC34520 | Puller | Obsolete - replaced by PWC50781 and PWC50782 |
| PWC50781 | Puller | Alternative to PWC34520 |
| PWC50782 | Puller | Alternative to PWC34520 |
| (1) | Remove lockwire and loosen coupling nut (23). Remove two bolts (13) and remove fuel tube (15) . Remove and discard preformed packing (14) . |
| (2) | Remove restrictor and expansion plug (24) from fuel tube (15) using puller (PWC34520 or (PWC50781) or PWC50782). |
| (3) | Remove nut (25) , bolt (26) and loop clamp (28) . |
| (4) | Remove two bolts (30) and fuel tube (29) . Remove and discard preformed packing (31) . |
| (1) | Remove lockwire and loosen coupling nut (21). |
| (2) | Remove two bolts (11) and remove fuel tube (16) . Remove and discard preformed packing (12) . |
| (3) | Remove lockwire and loosen coupling nut (5). |
| (4) | Remove nut (17) , washer (18) , spacer (19) and bolt (20) . |
| (5) | Remove fuel tube (6) and loop clamp (22) . |
| (6) | Remove two bolts (9) , two washers (8) and remove bracket (7) . |
| (7) | Remove two bolts (2) and fuel tube (4) . Remove and discard preformed packing (3) . |
| (1) | Disconnect coupling nut between tube assembly (1) and tube assembly (2) . |
| (2) | Disconnect tube assembly (1) from the spacer (16). |
| (3) | Remove two bolts (4) from tube assembly (2). |
| (4) | Remove nuts (7) , bolts (5) and loop clamps (6) from tube assemblies (1 and 2). |
| (5) | Remove tube assembly (1). |
| (6) | Remove tube assembly (2) from the dump valve assembly. |
| (7) | Remove and discard the preformed packing (3) from tube assembly (2). |
| (8) | For Pre-SB25193:
|
| (11) | For Post-SB25193:
|
| (14) | Remove two bolts (14) , two washers (15) and remove bracket (13). |
| (15) | Remove the plug and spacer assembly (16). |
| (16) | Remove bolts (18) . |
| (17) | Remove fuel pressure tube (17) . |
| (18) | Remove and discard preformed packing (19) . |
| (1) | Secure fuel tube (15) in soft jawed vise and insert fuel pressure restrictor (24) . Secure with expansion plug. Drive plug into tube, flush with end of tube to within 0.005 inch (Table 204, REF. NO. 3803). |
| (2) | Lubricate new preformed packing (14) with engine oil (PWC03-001) and install on fuel tube (15). Install fuel tube on dump valve with two bolts (13) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (3) | Lubricate new preformed packing (31) with engine oil (PWC03-001) and install on fuel tube (29) . Install fuel tube on HMU with two bolts (30) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (4) | Assemble fuel tube (29) to fuel tube (15) loosely with coupling nut (23). |
| (5) | Assemble loop clamps (27) and (28) to fuel tubes with bolt (26) and nut (25) . Torque 27 to 30 lb.in. (3.1-3.4 Nm). |
| (6) | Hold flats of fuel tube and torque coupling nut (23) 90 to 100 lb.in. (10.2-11.3 Nm) and lockwire (PWC05-089). |
| (1) | Lubricate new preformed packing (3) with engine oil (PWC03-001) and install on fuel tube (4) . Secure fuel tube to HMU (1) with two bolts (2) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Position fuel tube (6) on fuel tube (4) and secure with coupling nut (5). Tighten with fingers. |
| (3) | Loosely assemble bracket (7) to dump valve (10) with two bolts (9) and washers (8) . Tighten with fingers. |
| (4) | Loosely assemble loop clamp (22) to fuel tube (6) and bracket (7) with bolt (20) , spacer (19) , washer (18) and nut (17) . Tighten with fingers. |
| (5) | Position fuel tube (16) on the fuel tube (6) and secure with coupling nut (21). Tighten with fingers. |
| (6) | Lubricate new preformed packing (12) with engine oil (PWC03-001) and install on fuel tube (16). Install fuel tube (16) on dump valve (10) and fuel tube (6). Tighten coupling nut (21) with fingers. |
| (7) | Secure fuel tube (16) to dump valve (10) with two bolts (11) . Torque 36 to 40 lb.in. (3.1-3.4 Nm). |
| (8) | Torque bolts (9) 36 to 40 lb.in. (4.1-4.5 Nm). Torque nut (17) 27 to 30 lb.in. (3.1- 3.4 Nm). |
| (9) | Hold flats of fuel tubes (4 and 6) and torque coupling nuts (5 and 21) 450 to 500 lb.in. (50.8-56.5 Nm) and lockwire (PWC05-089). |
| (1) | Install packing (19) on tube (17) . Attach tube with two bolts (18) . Tighten with fingers. |
| (2) | Install plug and spacer assembly (16). Tighten plugs with fingers. |
| (3) | For Pre-SB25193:
|
| (6) | For Post-SB25193:
|
| (9) | Install preformed packing (3) on tube assembly (2) . Attach tube assembly (2) with two bolts (4) . Tighten bolts with fingers. |
| (10) | Install tube assembly (1) . |
| (11) | Tighten tube (1) and tube (2) coupling nuts with fingers. |
| (12) | Install seven loop clamps (6) , bolts (5) and nuts (7) . Tighten nuts with fingers. |
| (13) | Torque two bolts (14) and two bolts (18) 36 to 40 lb.in. (4-4.5 Nm). |
| (14) | Torque two nuts (9) on the clamp set (10) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (15) | Torque the coupling nut between tube (1) and tube (2) 270 to 300 lb.in. (30.5-33.9 Nm). |
| (16) | Torque nuts (7) 36 to 40 lb.in. (4-4.5 Nm). |
| (1) | Remove nut (13) , bolt (15) , two loop clamps (16) and spacer (14) . |
| (2) | Remove lockwire and loosen coupling nut (21). |
| (3) | Remove two bolts (12) and remove fuel tube (20) . Discard preformed packing (11) . |
| (4) | Remove lockwire, loosen coupling nuts (9 and 18) and remove fuel tube (17) . |
| (5) | Remove lockwire and loosen coupling nuts (6 and 8). |
| (6) | Remove fuel tube (23) withdraw strainer element (5). |
| (1) | Install strainer element (5) into fuel tube (23) and position fuel tube (23) on fuel tube tee (3). Move coupling nut (6) back, to ensure cone of strainer is sandwiched between tube and nipple. Tighten coupling nuts (6 and 8) and torque 135 to 150 lb.in. (15.3-17.0 Nm) and lockwire (PWC05-089). |
| (2) | Install fuel tube (17) . Torque coupling nuts (9 and 18) 90 to 100 lb.in. (10.2-11.3 Nm) and lockwire (PWC05-089). |
| (3) | Lubricate new preformed packing (11) with engine oil (PWC03-001) and install on fuel tube (20) . |
| (4) | Install fuel tube (20) on HMU with two bolts (12) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (5) | If necessary, align elbow (22) with fuel tube (20). Hold elbow and torque coupling nut (21) 90 to 100 lb.in. (10.2-11.3 Nm). Torque coupling nut securing elbow (22) to ejector tank 38 to 42 lb.in. (4.3-4.8 Nm) and lockwire (PWC05-089) both coupling nuts . |
| (6) | Install two loop clamps (16) with spacer (14) , nut (13) and bolt (15) . Torque 27 to 30 lb.in. (3.1-3.4 Nm). |
| (1) | Remove two nuts (5) and bolts (17) . |
| (2) | Remove fuel pressure tube (2) from engine and discard preformed packings (6) and (18) . |
| (3) | Remove nut (12) , bolt (9) and loop clamp (10) . |
| (4) | Remove lockwire and loosen coupling nut (14). |
| (5) | Remove two nuts (7) and bolts (15) . |
| (6) | Remove fuel pressure tube (4) from engine and discard preformed packings (8) and (16) . |
| (1) | Lubricate new preformed packings ( (8) and (16) , Fig. ) with engine oil (PWC03-001) and install on fuel pressure tube (4) . |
| (2) | Install fuel tube (4) on HMU and fuel filter housing with two bolts (15) and two nuts (7) . Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). Torque nuts 27 to 30 lb.in. (3.1-3.4 Nm). |
| (3) | Position coupling nut (14) on tee of fuel tube (4). Ensure cone of strainer element is properly positioned in fuel tube (Ref. Fig. ). Torque coupling nut 135 to 150 lb.in. (15.3-17.0 Nm) and lockwire (PWC05-089). |
| (4) | Install loop clamp (10) (Fig. ) with bolt (9) and nut (12) . Torque 27 to 30 lb.in. (3.1-3.4 Nm). |
| (5) | Lubricate new preformed packings (6) and (18) with engine oil (PWC03-001) and install on fuel tube (2) . |
| (6) | Install fuel tube (2) with two bolts (17) and two nuts (5) . Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). Torque nuts 27 to 30 lb.in. (3.1-3.4 Nm). |
| (1) | Remove nut (13) , bolt (11) and loop clamp (12) (Ref. View C). |
| (2) | Remove nut (17) , bolt (15) and loop clamp (27) (Ref. View D). |
| (3) | Remove two bolts (5) and two bolts (19) . |
| (4) | Remove fuel bypass tube (2) from engine and discard preformed packings (6) and (18) . |
| (5) | Remove nut (7) , bolt (9) and loop clamp (8) (Ref. View B). |
| (6) | Remove nut (23) , bolt (21) and loop clamps (20) (Ref. View F). |
| (7) | Remove two bolts (3) and two nuts (25) . |
| (8) | Remove fuel bypass tube (1) from engine and discard preformed packings (4) and (24) . |
| (1) | Lubricate new (4) and (24) and install on fuel bypass tube (1) . |
| (2) | Install fuel bypass tube (1) using bolts (3) and two nuts (25) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). Torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (3) | Install loop clamp (8) with bolt (9) and nut (7) (Ref. View B). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (4) | Install two loop clamps (20) with bolt (21) and nut (23) (Ref. View F). Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (5) | Lubricate new performed packings (6) and (18) and install on fuel bypass tube (2) . Install fuel bypass tube on engine with two bolts (5) and (19) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Install loop clamp (12) with bolt (11) and nut (13) (Ref. View C). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Install loop lamps (14) and (27) with bolt (15) and nut (17) (Ref. View D). Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Remove nut (7) , bolt (5) and loop clamps (6) . |
| (2) | Remove nut (17) , bolt (16) and loop clamp (18) . |
| (3) | Remove bolts (13) and (10) and remove fuel pressure tube (1) . Discard preformed packings (11) and (14) . |
| (4) | Remove fuel strainer (15) . |
| (5) | Remove bolts (3) and (8) and remove fuel pressure tube (4) . Discard preformed packings (2) and (9) . |
| (6) | Remove fuel strainer (15). |
| (1) | Lubricate new preformed packings (2) and (9) with engine oil (PWC03-001) and install on fuel pressure tube (4) . |
| (2) | Install fuel strainer (15) . |
| (3) | Install fuel pressure tube (4) with bolts (3) and (8) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (4) | Lubricate new preformed packings (11) and (14) with engine oil (PWC03-001) and install on fuel pressure tube (1) . |
| (5) | Install fuel strainer (15). |
| (6) | Install fuel pressure tube (1) with bolts (10) and (13) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Install two loop clamps (6) with bolt (5) and nut (7) . Torque 27 to 30 lb.in. (3.10-3.4 Nm). |
| (8) | Install loop clamp (18) to bracket (15) and secure with bolt (16) and nut (17) . Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Disconnect airframe fuel supply from fuel pump inlet (Ref. Airframe Maintenance Manual) and cap openings. |
| (2) | Remove lockwire and loosen coupling nut (3). |
| (3) | Remove four bolts (14) and washers (13) . |
| (4) | Install two jacking screws (thread size 0.250-28 UNJF) in flange of fuel pump (11) (Ref. View A). |
| (5) | Remove fuel pump from HMU (1) by turning jacking screws inwards. |
| (6) | If fuel pump driveshaft disconnects from fuel pump, remove the fuel pump driveshaft from AGB gearshaft. Make sure not to damage the gearshaft spline and retaining clip. |
| (7) | Remove and discard preformed packings
(5)
,
(6)
,
(7)
,
(9)
, and
(10)
and
packing retainer (8)
.
NOTE: The fuel pump driveshaft preformed packing (5) may have been removed as part of
HMU removal (Ref. 73-20-01, HYDROMECHANICAL METERING UNIT - MAINTENANCE PRACTICES).
|
| (8) |
Post-SB25290: NOTE: The fuel pump is an integral part of the
Post-SB25290 hydromechanical fuel control unit. Removal of the fuel pump from the
Post-SB25290 HMU is not required, however removal of fuel pump driveshaft packing is required
(Ref. 73-20-01, HYDROMECHANICAL METERING UNIT (HMU) - MAINTENANCE PRACTICES).
|
| (9) | Remove nipple (16) and discard preformed packing (15) . |
| (1) | Install new preformed packing (15) on nipple (16) and install nipple in fuel pump (11) . Torque 65 to 75 lb.in. (7.5-8.5 Nm). |
| (2) |
Post-SB25290: NOTE: The fuel pump is an integral part of the
Post-SB25290 hydromechanical fuel control unit. Installation of the fuel pump in the
Post-SB25290 HMU is not required, however installation of a new fuel pump driveshaft packing is
required before HMU installation (Ref. 73-20-01, HYDROMECHANICAL METERING UNIT (HMU) - MAINTENANCE PRACTICES).
|
| (3) | Lubricate new preformed packings (5) , (6) , (7) , (9) and (10) and packing retainer (8) with engine oil (PWC03-001) and install on fuel pump. |
| (4) | If fuel pump driveshaft has separated from fuel pump assembly, install the fuel pump
driveshaft to the fuel pump assembly. Before assembly inspect as follows:
|
| (9) | Align locating pin (2) on HMU interface with hole (12) in fuel pump flange. Carefully insert fuel pump into HMU. |
| (10) | Attach fuel pump with four bolts (14) and washers (13) . Torque 85 to 95 lbf.in. (9.6 - 10.7 Nm). |
| (11) | Connect fuel waste ejector return tube (4) to fuel pump (11) with coupling nut (3). Torque 90 to 100 lb.in. (10.2-11.3 Nm) and lockwire (PWC05-089). |
| Tool No. | Name |
|---|---|
| PWC30128-11 | Puller |
| PWC60786 | Pressure Test Kit |
| PWC60787 | Adapter Plate |
| PWC60788 | Lapping Handle |
| PWC90010 | Expander |
| (1) | Remove the fuel pressure tubes from the fuel filter housing (Ref. Ch. 73-10-01). |
| (2) | Remove the oil pressure differential switch two mounting bolts from the filter housing and remove the electrical connector to the fuel pressure differential switch (Ref. Ch. 79-30-02). |
| (3) | Support fuel filter housing (1) and remove two bolts (3), washers (2), bolt (5) and bracket (4) and remove fuel filter housing from accessory gearbox. |
| (4) | Place protective covers on all fuel filter housing openings. |
| (5) | Place removed parts in sealable plastic bags and identify with names and part numbers of contents. |
| (1) | Remove three nuts (11) and flat washers (12) and remove fuel filter cover (10) from fuel filter housing assembly (25) . Remove and discard preformed packing (13) . |
| (2) | Remove retaining ring (9) and fuel filter element (7) from fuel filter cover. Remove and discard preformed packing (8) . |
| (1) | Remove two nuts (2) and flat washers (1) and carefully remove fuel filter impending bypass switch (3) and spring (5) . Remove and discard preformed packings (4) and (6) . |
| (2) | Remove filter bypass valve (26) from fuel filter housing (25) . |
| (1) | Remove lockwire and remove machine thread plug (16) . Remove and discard preformed packing (17) . |
| (2) | Remove plug (16) and discard preformed packing (17). |
| (3) | Remove two nuts (14) , two washers (27) and remove fuel filter drain adapter (15) using puller (PWC30128-11). Remove and discard preformed packing (18) . |
| (1) | Remove lockwire and remove bleeder tube plug (21) . Remove and discard preformed packing (20) . |
| (2) | Remove two nuts (22) and flat washers (23) . Remove air bleed adapter (19) . Remove and discard preformed packing (24) . |
| (3) | Place all removed parts in clean, sealable plastic bags and tag with part numbers and description of contents. |
| (1) | Mount fuel filter housing on adapter plate (PWC60787) and secure adapter plate in vise. |
| (2) | Apply a thin even coat of layout dye (PWC05-041) to face of bypass valve (26) . |
| (3) | Insert valve (26) into fuel filter housing (25) , allowing valve to contact valve seat. |
| (4) | Remove valve from housing and inspect. A continuous ring around contact area should be visible. A broken ring will indicate incomplete valve seating. |
| (5) | Thoroughly clean valve face and valve seat (Ref. Cleaning). |
| (6) | Apply engine oil to valve face. |
| (7) | Using lapping compound (PWC05-019) and lapping handle (PWC60788), lap valve face to valve seat. |
| (8) | Thoroughly clean parts using clean varsol (Ref. Cleaning). |
| (9) | Verify valve seating and repeat procedure until satisfactory result is obtained. |
| (1) | Install bypass valve (26) and spring (5) into housing (25) . |
| (2) | Lubricate the threads and two new preformed packings (4) and (6) with engine oil (PWC03-001). |
| (3) | Install preformed packings (4 and 6) on the fuel filter impending bypass switch (3) with expander (PWC90010). |
| (4) | Install fuel impending bypass switch (3) on fuel filter housing (25) and attach with
two
flat washers (1)
and self-locking
nuts (2)
. Torque nuts 23 to 26 lb.in. (2.6-3.0 Nm).
NOTE: Do not lubricate the self-locking nuts and flat washer.
|
| (5) | Functionally check bypass valve as follows:
|
| (1) | Lubricate new preformed packing (24) and install on air bleed adapter (19) . |
| (2) | Install air bleed adapter (19) on fuel filter housing (25) and secure with two flat washers (23) and self-locking nuts (22) . Torque nuts 23 to 26 lb.in. (2.6-3.0 Nm). |
| (3) | Lubricate new preformed packing (20) and install on bleeder tube plug (21) . Install plug into adapter (19) and torque 40 to 50 lb.in. (4.6-5.6 Nm). |
| (4) | Lubricate new preformed packing (13) and install on fuel filter cover (10) . |
| (5) | Lubricate new preformed packing (8) and install on fuel filter element (7) . Install filter element into filter cover (10) and secure with retaining ring (9) . |
| (6) | Lubricate new preformed packing (18) and install on fuel filter drain adapter (15) . Install adapter on fuel filter housing (25) and secure with two nuts (14) and washers (27) . Torque nuts 23 to 26 lb.in (2.6-3.0 Nm). |
| (7) | Lubricate new preformed packing (17) and install on machine thread plug (16) . Install plug into adapter (15). Torque plug 65 to 75 lb.in. (7.5-8.0 Nm) and lockwire (PWC05-089). |
| (8) | Install fuel filter cover assembly (10) to the fuel filter housing (25) and secure with three flat washers (12) and self-locking nuts (11) . Torque nuts 23 to 26 lb.in (2.6-3.0 Nm). |
| (9) | Remove housing assembly from holding fixture. |
| (10) | Place protective covers on all fuel filter housing openings. |
| (11) | Place assembled fuel filter housing in clean, sealable plastic bag and tag with description and part number of contents. |
| (1) | Locate fuel filter housing (1) on two dowel pins on accessory gearbox and secure with two washers (2) and bolts (3). Torque bolts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (2) | Install bracket (4) and bolt (5) in bottom mounting hole of fuel filter housing. Torque bolt 27 to 30 lb.in. (3.0-3.4 Nm). |
| (3) | Install the fuel pressure tubes from the fuel filter housing (Ref. Ch. 73-10-01). |
| (4) | Install the oil pressure differential switch two mounting bolts from the filter housing (Ref. Ch. 79-30-02) and install the electrical connector to the fuel pressure differential switch. |
| (1) | Disconnect Channel B N2 speed sensor connector, to improve tool access to filter cover (Ref. Ch. 77-10-01). |
| (2) | Remove three nuts (8) , washers (7) , one nut (18) and washer (17) and separate shield (16) and filter cover (6) from filter housing (1) . Remove and discard preformed packing (5) . |
| (3) | Remove retaining ring (2) from filter cover (6) and remove fuel filter (4) . Remove and discard preformed packing (3) . |
| (1) | Install fuel filter element (4) in filter cover (6) and secure with retaining ring (2) . |
| (2) | Lubricate new preformed packing (3) with engine oil (PWC03-001) and install in fuel filter element (4). |
| (3) | Lubricate new preformed packing (5) with engine oil (PWC03-001) and install in filter cover (6). |
| (4) | Install filter cover assembly on fuel filter housing (1) and secure with three nuts (8) and washers (7) . Tighten and torque nuts 23 to 26 lb.in (2.6-3.0 Nm). |
| (5) | Re-connect Channel B N2 speed sensor connection (Ref. Ch. 77-10-01). |
| (1) | Loosen nut (16) on transfer tube (15) and disconnect tube from waste ejector inlet elbow (14) . |
| (2) | Loosen nuts (7 and 9) and disconnect transfer tubes (6) and (10) from outlet fitting (8). |
| (3) | Support fuel waste ejector (4) and remove bolts (1) , nuts (5) and washers (2) securing ejector to mounting bracket (3) . |
| (4) | Install protective caps and/or plugs on exposed openings. |
| (5) | Pre-SB25194: If necessary, remove mounting bracket (3) from outer bypass duct (19) by removing bolts (17) and washers (18) , three places. |
| (6) | Post-SB25194: If necessary, remove mounting bracket (3) from outer bypass duct (19) by removing bolts (17) , washers (18) and gaskets (20) , three places. |
| (1) | Pre-SB25194: If removed, install mounting bracket (3) on outer bypass duct (19) with bolts (17) and washers (18) , three places. Torque nuts 36 to 40 lb.in (4.0 to 4.6 Nm). |
| (2) | Post-SB25194: If removed, Install mounting bracket (3) on outer bypass duct (19) with bolts (17), washers (18) and gaskets (20) , three places. Torque nuts 36 to 40 lb.in (4.0 to 4.6 Nm). |
| (3) | If necessary, install fittings on fuel waste ejector as follows:
|
| (6) | Locate fuel waste ejector (4) on mounting bracket (3) and secure with four bolts (1) , washers (2) and self-locking nuts (5) . Tighten and torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Align tubes (6) and (10) with ejector fitting (8). Secure with nuts (7 and 9), tighten and torque nuts 90 to 100 lb.in. (10.2-11.3 Nm). |
| (8) | Align transfer tube (15) with elbow (14). Hold elbow, tighten and torque nut (13) 38 to 42 lb.in. (4.3 - 4.8 Nm). Hold elbow, tighten and torque nut (16) 90 to 100 lb.in. (10.2-11.3 Nm). |
| (9) | Lockwire (PWC05-089) nuts (7 and 9). |
| (1) | Wash parts in clean petroleum solvent (PWC11-027). If necessary, use a nylon bristle brush to remove contaminants. |
| (2) | Dry parts using clean, dry, filtered compressed air blast, or allow parts to stand and air dry. |
| (1) | Insert a small lamp into the inside bore of the filter element. |
| (2) | Visually inspect filter element for breaks, punctures or evidence of collapse. There must be no loose particles, broken bonds or joints. |
| Tool No. | Name |
|---|---|
| PWC43572 | Locator, 3 req'd |
| PWC60710 | Clamp |
| PWC60711 | Adaptor |
| PWC60712 | Plug |
| PWC60718 | Test Kit |
| PWC61792 | Leak Check Fixture |
| (1) | Remove nuts (7, Fig. ), washers (6) , gaskets (22) and outer cover (5) . Discard gaskets. |
| (2) | Remove nuts (25, Fig. ), washers (26), bolts (24) and bottom fairing (23). |
| (3) | Remove bolts (3, Fig. ) and inner duct segment (4). |
| (4) | Remove bolt (13, Fig. ) and nut (14) that attaches tube bracket to the No. 4 scavenge oil tube. |
| (5) | Remove two bolts (7) securing fuel tube assembly (6) to bypass duct. |
| (6) | Remove bolt (11) and self-locking nut (4) securing loop clamp (5) to angle bracket (10). |
| (7) | Remove and discard lockwire securing two coupling nuts (3). |
| (8) | Loosen two coupling nuts (3) and remove primary fuel tube assembly (6). |
| (9) | Remove two transfer tubes (2) . Remove and discard four preformed packings (1) . |
| (10) | Remove and discard two preformed packings (8) and (9) . |
| (11) | Remove loop clamp (5) from primary fuel tube assembly (6). |
| (12) | Install closures on all exposed openings. |
| (1) | Position loop clamp (5) on primary fuel tube assembly (6) . |
| (2) | Lubricate and install two new preformed packings (8) and (9) on primary fuel tube assembly (6). |
| (3) | Lubricate and install four new preformed packings (1) on two fuel transfer tubes (2) . |
| (4) | Insert two fuel transfer tube assemblies (2) into two primary fuel nozzle assemblies (12). |
| (5) | Install primary fuel tube assembly (6) by pushing adapter into outer bypass duct into two fuel transfer tubes (2) into primary fuel nozzles. |
| (6) | Install bolt (13) and nut (14) to loop clamp (15) securing tube bracket to the No. 4 scavenge oil tube. Torque nut (14) 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Secure tube adapter to outer bypass duct using two bolts (7) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Lubricate threads of coupling nuts (3) with mixture of 20% engine oil (PWC03-001) and 80% anti-sieze compound (PWC06-004A). |
| (9) | Secure two coupling nuts (3) to two primary fuel nozzles (12). Torque 225 to 250 lb.in. (25-28 Nm). |
| (10) | Lockwire (PWC05-089) two coupling nuts (3) to bolts securing primary fuel nozzles. |
| (11) | Secure loop clamp (5) to angle bracket (10) using bolt (11) and nut (4) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (12) | Refer to Chapter 71-00-00 for required checks following installation of primary fuel tubes. |
| (13) | Install inner duct segment (4, Fig. ) with bolts (3). Tighten 36 to 40 lb.in. (4.0-4.5 Nm). |
| (14) | Install the bottom fairing (23, Fig. ) with bolts (24), washers (26) and nuts (25). |
| (15) | Install outer cover (5, Fig. ), gaskets (22) , washers (6) and nuts (7) . Make sure gaskets are between duct and washers. Tighten nuts 23 to 26 lb.in (2.6-2.9 Nm) in a star pattern from top center of cover outward. |
| (1) | Remove ignition exciters and mounting plate (Ref. 74-10-01). |
| (2) | Remove primary fuel tube assembly (Ref. Para. ).
NOTE: Primary fuel tube assembly must be fully removed from engine before primary nozzles
removed.
|
| (3) | Remove three bolts (13) and three retaining plates (14) and push back three outer tubes (11) . |
| (4) | Remove two bolts (15) and remove two primary fuel nozzles (12) . |
| (5) | Discard gaskets (16) and preformed packings (8) and (9) . |
| (1) | Install new preformed packings (8) on nozzles (12) . |
| (2) | Install new preformed packings (9) on inner fuel tubes (10) . |
| (3) | Slide one outer fuel tubes (11) on fuel manifold. Slide remaining two outer fuel tubes on fuel nozzles (12). |
| (4) | Install new gaskets (16) on fuel nozzles and insert nozzles into bosses in combustor outer case. |
| (5) | Secure each fuel nozzle with one bolts (15) , fingertight. |
| (6) | Connect fuel nozzles with fuel manifold by sliding outer fuel tubes (11) into place. |
| (7) | Install outer fuel tubes in place with three retaining plates (14) and bolts (13) , fingertight. |
| (8) | Tighten bolts (13 and 15) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (9) | Install primary fuel tube assembly (Ref. Para. ). |
| (10) | Install inner duct segment (4) with bolts (3). Tighten 36 to 40 lb.in. (4.0-4.5 Nm). |
| (11) | Install outer cover (5) , gaskets (22) , washers (6) and nuts (7) . Make sure gaskets are between duct and washers. Tighten nuts 23 to 26 lb.in (2.6-2.9 Nm) in a star pattern from top center of cover outward. |
| (12) | Refer to Chapter 71-00-00, ADJUSTMENT/TEST, for required checks following installation of fuel nozzles. |
| (1) | Remove upper segments of outer bypass duct (Ref. Chapter 72-70-01) |
| (2) | Remove inner bypass ducts (Ref. Chapter 72-70-01) |
| (3) | Remove 21 bolts (8, Fig. ) and tube retaining plates (9) . |
| (4) | Slide 21 fuel manifold tube assemblies (6) back, to disengage from adjacent fuel nozzle. |
| (5) | Remove three bolts (10) and three fuel nozzles (2) 120 degrees apart, and install three locators (PWC43572). |
| (6) | Remove start and dump valve (Ref. Chapter 73-10-05, FUEL SHUTOFF AND DRAIN - MAINTENANCE PRACTICES). |
| (7) | Remove fuel shut off valve and transfer tubes (Ref. Chapter 73-10-05, FUEL SHUTOFF AND DRAIN - MAINTENANCE PRACTICES). |
| (8) | Remove one bolt (10) and fuel inlet nozzle (1) . |
| (9) | Remove remaining 20 bolts (10) and fuel nozzles (2). Completely remove one nozzle before proceeding to the next. |
| (10) | Remove and discard 22 metal gaskets (11) from 21 fuel nozzles (2) and one fuel inlet nozzle (1). |
| (11) | Remove 22 fuel manifold tube assemblies (6) from fuel nozzles and fuel inlet nozzle. |
| (12) | Remove and discard 44 preformed packings (3) from fuel nozzles and fuel inlet nozzle. |
| (13) | Remove 22 inner fuel manifold tubes (5) from 22 outer fuel manifold tubes (7) . Remove and discard 44 preformed packings (4) . |
| (14) | Remove inner and outer manifold tubes (10) and (11) , (Fig. ) from adjacent primary nozzles. |
| (15) | Remove and discard preformed packings (9) . |
| (16) | Remove primary manifold and nozzles (Ref. Subpara. ). |
| (17) | Place closures over all openings of fuel nozzles and fuel inlet nozzle and place in individual containers. |
| (1) | Lubricate preformed packings (4, Fig. ) with engine oil (PWC03-001) and install on 21 inner fuel manifold tubes (5) . |
| (2) | Lubricate preformed packings (9, Fig. ) with engine oil (PWC03-001) and install on one inner fuel manifold tube (10) . |
| (3) | Introduce one inner manifold tube (10), with side having an extra shoulder, into one outer manifold tube (11) , through end with flats. Thread inner manifold tube (10) into outer manifold tube (11) until threaded shoulder on inner tube is trapped between shoulders on outer tube. |
| (4) | Introduce inner manifold tubes (5, Fig. ) with side having an extra shoulder, into outer manifold tubes (7) through end with flats. Thread inner manifold tube (5) into outer manifold tube (7) until threaded shoulder on inner tube is trapped between shoulder on outer tube. |
| (5) | Lubricate preformed packings (3) with engine oil (PWC03-001) and install on inlet nozzle (1) . |
| (6) | Lubricate remaining preformed packings (3) with engine oil (PWC03-001) and install on fuel nozzles (2) . |
| (7) | Lubricate preformed packing (8, Fig. ) with engine oil (PWC03-001) and install on one fuel nozzle (2, Fig. ) |
| (8) | Insert outer fuel tube assembly (11, Fig. ) into one fuel nozzle (2, Fig. ).
NOTE: Insert end of tube assembly without flats, into grooved end of fuel nozzle.
|
| (9) | Insert
fuel manifold tube assemblies
, (6, Fig. ) into fuel nozzles (2) and one primary fuel nozzle (1).
NOTE: Insert end of tube assembly without flats, into grooved end of fuel nozzle.
|
| (10) | Install metal gaskets (11) on 21 fuel nozzles (2) and one fuel inlet nozzle (1). |
| (11) | Insert fuel inlet nozzle (1) in combustion chamber outer case assembly, at bottom centre location. Make sure nozzle enters combustion chamber. Install bolt (10) fingertight. |
| (12) | Install the fuel shut off valve with transfer tubes (Ref. Chapter 73-10-05, FUEL SHUTOFF AND DRAIN - MAINTENANCE PRACTICES). |
| (13) | Install the start and dump valve (Ref. Chapter 73-10-05, FUEL SHUTOFF AND DRAIN - MAINTENANCE PRACTICES). |
| (14) | Insert fuel nozzle assemblies (2) in combustion chamber outer case assembly, leaving two open bosses for primary fuel nozzles (Ref. View looking forward on fuel manifold). Install bolts (10) fingertight. |
| (15) | Slide fuel manifold tube assemblies (6) over fuel nozzles until retaining plate locking grooves are exposed. |
| (16) | Insert one tube retaining plate (9) into locking groove of fuel inlet nozzle (1). Install bolt (8) fingertight. |
| (17) | Insert tube retaining plates (9) into locking grooves in fuel nozzles (2) with bolts (8) fingertight. |
| (18) | Install primary manifold and fuel nozzles (Ref. Subpara ). |
| (19) | Tighten bolts (8 and 10) 36 to 40 lb.in. (4.0-4.6 Nm). |
| (20) | Install inner bypass duct (Ref. Chapter 72-70-01). |
| (21) | Install upper segments of outer bypass duct (Ref. Chapter 72-70-01). |
| (22) | Refer to Chapter 71-00-00 for checks required following installation of fuel manifold and nozzles. |
|
Fuel nozzles are to be returned for cleaning and inspection to:
Pratt & Whitney Component Solutions
4905, Stariha drive,
Muskegon
MI 49441
TEL: (231) 798-8464
FAX: (231) 798-0150
Or you can clean and inspect fuel nozzles in accordance with the following procedure: |
| (1) | The cleaning solutions listed (Ref. Table ) are recommended for immersion or ultrasonic cleaning of fuel nozzles: |
| (2) | Make a solution of cleaning agent (Ref. Table ) in water. Tap water may be used. Add the cleaning agent slowly to the water. Agitate the mixture to evenly mix the concentration. |
| (3) | Heat the solution to 179 to 199°F (82-93°C). |
| (4) | Clean the nozzle by immersion or ultrasonic method.
|
| (11) | Check that the carbon is removed from the tip. If carbon deposits are still present on the tip, use a nylon bristle brush to loosen the carbon. |
| (12) | Repeat the cleaning until carbon is removed. |
| (13) | Put the nozzle fully into the cold water, then in water heated to 150 to 199°F (66 to 93°C). Keep nozzle in the tank until the temperature of the part is the same as the water temperature. |
| (14) | Remove the nozzle and dry by blowing with clean, oil free shop air. |
| (15) | Repeat the process for each nozzle. |
| (1) | For the fuel nozzle visual inspection, refer to Component Maintenance Manual P/N 3070814. |
| (1) | Install plug (PWC60712) (1) in main fuel passage of fuel inlet nozzle (2). |
| (2) | Install inlet adaptor (PWC60711) (3) in fuel inlet nozzle (2) and lock in place using locking clamp (PWC60710) (4). |
| (3) | Connect pressure test kit (PWC60718) to inlet adaptor (3). |
| (4) | Make sure test kit selector valve (6) is set in the OFF/TEST position. |
| (5) | Make sure pressure regulator valve (7) is closed (if regulator is not preset). |
| (6) | Open the shut off valve on the nitrogen cylinder (PWC05-050). |
| (7) | Adjust pressure regulator valve (7) until pressure is 100 to 150 psi (689.4-1034.2 kPa), if regulator is not preset. |
| (8) | Turn selector valve (6) to the COMBUSTOR position. |
| (9) | Make sure test kit pressure is 100 to 150 psi (689.4-1034.2 kPa). |
| (10) | Turn selector valve (6) to the OFF /TEST position. |
| (11) | Close the shut off valve on nitrogen cylinder. |
| (12) |
Monitor test kit pressure gauge for 5 minutes minimum.
|
| (18) | Turn selector valve (6) to BLEED OFF position. |
| (19) | Close pressure adjusting valve (7) on nitrogen cylinder (if regulator is not preset). |
| (20) | Remove clamp (4), test adapter (3), plug (1) and test kit (5). |
| (1) | Disconnect the nacelle drain line from drain adapter (1), (Ref. Aircraft Maintenance Manual). |
| (2) | Connect hose assembly (6) of leak check fixture (PWC61792) (5) to drain adaptor (1). |
| (3) | Make sure test kit selector valve (3) is set in the OFF /TEST position. |
| (4) | Make sure the regulator valve on cylinder (2) containing nitrogen (PWC05-050) is closed. |
| (5) | Open the shut off valve on nitrogen cylinder (2). |
| (6) | Adjust pressure regulator valve on cylinder (2) until pressure is 100 to 150 psi (689.4-1034.2 kPa). |
| (7) | Turn selector valve (3) to the TO COMBUSTER position. |
| (8) | Make sure gauge (4) reads 100 to 150 psi (689.4-1034.2 kPa). |
| (9) | Turn selector valve (3) to the OFF /TEST position. |
| (10) | Close the shut off valve on nitrogen cylinder (2). |
| (11) |
Monitor test kit pressure gauge (4) for 5 minutes minimum.
|
| (17) | Turn selector valve (3) to BLEED OFF position. |
| (18) | Close pressure adjusting valve on nitrogen cylinder (2). |
| (19) | Remove hose assembly (6) from drain adapter (1). |
| (20) | Connect the nacelle drain line to drain adapter (1), (Ref. Aircraft Maintenance Manual). |
| Item No. | Name |
|---|---|
| PWC03-001 | Oil, Engine Lubricating |
| PWC05-089 | Lockwire |
| PWC05-344 | Safety Cable |
| PWC06-004B | Compound, Anti-seize |
| Tool No. | Name |
|---|---|
| PWC30128-6 | Puller |
| PWC58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Set maintenance discrete to ON. |
| (2) | Remove the P34 connector (2) and check the connector for moisture. If necessary, dry the connector with a suitable heatgun. |
| (3) | Remove flowmeter and related items (Ref. AMM). |
| (4) | Remove the bolts (3) , washers (4) and the dump valve from the fuel shut-off valve. |
| (5) | Remove the transfer tubes (6) and (7) from the dump valve. |
| (6) | Remove and discard the preformed packings (5) and (1) from the transfer tubes (6 and 7). |
| (1) | Install new preformed packings (5) and (1) on the transfer tubes (6 and 7). |
| (2) | Install the tubes (6) and (7) into the fuel dump valve. |
| (3) | Insert the fuel dump valve into the fuel shut-off valve. Make sure the transfer tubes are properly seated. |
| (4) | Install the washers (4) and the bolts (3) . Lubricate the bolts with engine oil (PWC03-001) and torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (5) | Install flowmeter and related items (Ref. AMM). |
| (6) | Do the following checks:
|
| (18) | Pull the EEC circuit breaker to OFF. |
| (19) | Function check the dump valve (Ref Subpara following). |
| (1) | Remove two bolts (11) and tube (12) from dump valve. |
| (2) | Remove and discard preformed packing (13). |
| (3) | Remove tube (11) from fuel waste ejector (Ref. 73-10-03). |
| (4) | Fit suitable slave fitting to the dump valve outlet and connect fitting to a large vented drain bottle. |
| (5) | Do a wet motoring run (Ref. 71-00-00) and check that fuel does not leak from the dump valve during motoring. |
| (6) | Continuous dripping of fuel from the dump valve during a wet motoring indicates a damaged valve. |
| (7) | After motoring, make sure dump valve drains residual fuel to the drain bottle. |
| (8) | If fuel does not drain, replace dump valve. |
| (9) | Remove slave fitting and drain bottle. |
| (10) | Lubricate new preformed packing (13) with engine oil (PWC03-001) and install on tube (8). Fit tube in place and secure to fuel dump valve with bolts (9 and 15). Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (11) | Install transfer tube (11) to fuel waste ejector (Ref. 73-10-03). |
| (12) | Restore engine to standard operating conditions. |
| (1) | Remove fuel start/dump valve (Ref. Para. ). |
| (2) | Remove lockwire and seal and loosen nuts (10) and (11) . Remove fuel shutoff cable (8) from fuel shutoff valve control lever. |
| (3) | Remove bolts (13) and flat washers (12) . Pull fuel shutoff valve (7) away from mounting pad and discard preformed packings (6) . |
| (4) | Remove transfer tubes (2) and (4) and discard preformed packings (1) , (3) and (5) . |
| (5) | Plug/cap all openings. |
| (1) | Lubricate two new preformed packings (6) with engine oil (PWC03-001), and install on fuel shutoff valve (7) . |
| (2) | Lubricate new preformed packings (1) , (3) and (5) with engine oil (PWC03-001), and install on transfer tubes (2) and (4) . Insert transfer tubes into fuel shutoff valve. |
| (3) | Install fuel shutoff valve on mounting pad of bypass duct, being careful to insert transfer tubes (2 and 4) into fuel inlet nozzle. Install four bolts (13) and washers (12) . Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (4) | Install fuel start/dump valve (Ref. Para. ). |
| (5) | Attach fuel shutoff cable (8) to fuel shutoff valve control lever and check adjustment. |
| (1) | Remove lockwire, seal, nuts (4) and spacer (3) securing fuel shutoff cable (2) to control lever (8) . |
| (2) | Remove two bolts (6) , washers (5) and remove overspeed control linkage housing (7) from fuel inlet and shutoff valve housing (1) . Ensure release plate (9) does not fall from assembly. |
| (3) | Push control lever (8) to slightly withdraw tripper sleeve assembly (15) , thus allowing control levers (13) to pivot freely. |
| (4) | Adjust control levers (13), using a soft-faced tool, to centralize with hole in tripper sleeve assembly (15). |
| (5) | Release pressure from control lever (8). Tripper sleeve (15) will snap into place if control levers (13) are centralized. Repeat steps (3) and (4), if necessary, until levers are reset. |
| (6) | Using a soft drift apply even pressure on tripper sleeve to make sure sleeve is fully seated. |
| (7) | Insert narrow end of release plate (9) between control levers (13) so that head of release plate contacts end of piston assembly in fuel inlet and shutoff valve assembly (1). |
| (8) | Fuel shutoff valve is now reset. |
| (9) | Measure Dimension AA between lug on tripper sleeve assembly (15) and rear face of control linkage housing (7). This dimension is used when installing the fuel shutoff cable. |
| (10) | Install control linkage housing (7) on fuel inlet and shutoff valve housing (1) with two bolts (6) and washers (5). Torque 36 to 40 lb.in. (4.0-4.5 Nm). |
| (11) | Adjust emergency fuel shutoff cable (Ref. Para. ). |
| (12) | Install lockwire (PWC05-089) and seal between nuts (4). |
| (1) | Visually inspect the cable mechanism for corrosion. |
| (2) | Borescope the cable mechanism in the exhaust case.
|
| (5) | Visually inspect the fuel shut off mechanism for corrosion. |
| (6) | Check for correct security (Ref. Para , Periodic Inspection). |
| (1) | Measure emergency fuel shut-off tripper Dim. T and record. |
| (2) | Using a soft drift apply even pressure on tripper sleeve (15) to make sure sleeve is fully seated. |
| (3) | Measure emergency fuel shut-off tripper Dim. T. Re-rig if Dim. T is less than 0.008 inch. |
| (4) | Do Engine Ground Checks No. 1 and No. 2 (Ref. 71-00-00). |
| (5) | Advance TLA to normal take-off detent. Hold in this position for as long as possible for a maximum of two minutes. Move TLA to ground idle to allow engine to stabilize. |
| (6) | Shut engine down per Check No. 3 (Ref. Ch. 71-00-00). |
| (7) | Check for security and leakage. |
| (1) | Carefully remove lockwire, lead seal, nuts (14) , (15) and spacer (16) from the lower end of control cable (7) . |
| (2) | Remove cable end from control lever. |
| (3) | Remove cotterpin (3) , pin (1) and cable end from bellcrank (2). Discard cotterpin (3). |
| (4) | Move bellcrank (2) to forward position and secure to exhaust case with lockwire (PWC05-089).
NOTE: This will prevent disengagement of cable from actuating lever inside exhaust case.
|
| (5) | Unlock keywasher (19) and remove with nut (18) . Discard key washer. |
| (6) | Remove nut (11) , bolt (9) and clamp (10) . |
| (7) | Remove lockwire and loosen nut (4). |
| (8) | Remove fuel shut-off cable from engine by pulling upwards through fairing of bypass duct (22). |
| (1) | If lower end of cable assembly (7) was not removed from bypass duct (22) or fuel shut-off valve control lever (13) go to step . |
| (2) | Put the threaded end of cable assembly (7) through holes at bottom of inner and outer bypass ducts (21, 22). |
| (3) | Install housing end of cable assembly on outer bypass duct with keywasher (19) and nut (18) . Torque nut 62 to 85 lb. in. (7.0-9.5 Nm.). Bend tabs on keywasher to lock nut. |
| (4) | Engage cable with pulley (17) of fuel shut-off valve and connect end of cable to control lever (13) with spacer (16) and nuts (15) , (14) , finger tight. |
| (5) | Install cable assembly (7) loosely to bracket (8) with clamp (10) , nut (11) and bolt (9) . |
| (6) | Remove nut (4) from cable housing and turn nut (6) all the way on. |
| (7) | Install cable assembly (7) through bracket (5) and loosely secure with nut (4). |
| (8) | Install cable end on exhaust case bell crank (2) with pin (1) and secure with cotterpin (3) . Remove lockwire from bellcrank. |
| (1) | Remove fuel waste ejector (Ref. 73-10-03). |
| (2) | Using a soft drift apply even pressure on tripper sleeve (15, Fig. ) to make sure sleeve is fully seated. |
| (3) | Measure and record dimension AA (Ref. Fig. ) from the lug on tripper sleeve assembly (15) to the rear face of
housing (7)
, using depth micrometer.
NOTE: Dimension AA = distance from end of tripper sleeve to end of housing before tightening
cable.
|
| (4) | If lower end of the
cable assembly
(7, Fig. ) was not removed from bypass duct (22) or fuel shut-off valve control lever (13),
set Dimension S as follows:
|
| (8) | Using a soft drift apply even pressure on tripper sleeve (15, Fig. ) to make sure sleeve is fully seated. |
| (9) | Set tension on tripper sleeve as follows:
CAUTION: DO NOT LUBRICATE THREADS.
CAUTION: DO NOT HAMMER FUEL SHUT-OFF VALVE TRIPPER SLEEVE.
|
| (15) | Lockwire (PWC05-089) nuts (4 and 6, Fig. ). |
| (16) | Lockwire (PWC05-089) nuts (14 and 15) and install suitable seal to nuts. |
| (17) | Install fuel waste ejector (Ref. 73-10-03). |
| (1) | Remove lockwire and fuel drain valve assembly (1). |
| (2) | Remove transfer tube (3) with puller (PWC30128-6). |
| (3) | Remove and discard preformed packings (2) , (4) and (5) . |
| (4) | If necessary, disassemble fuel drain valve assembly (1) by removing retaining ring (9) , drain valve (8) or (10) and spring (7) from drain valve adapter (6) . |
| (1) | Install lubricated preformed packings (4) and (5) on transfer tube (3) . |
| (2) | Install transfer tube (3), with pusher (PWC30128-6), through outer bypass duct into gas generator. |
| (3) | If necessary, assemble drain valve adapter assembly (1) as follows:
|
| (6) | Install drain valve adapter as follows:
|
| (13) | Secure fuel drain valve adapter (1) using lockwire (PWC05-089) or safety cable (PWC05-344). |
| (1) | Remove the aft body of the nacelle (Ref. AMM). |
| (2) | Remove the rear lower inner bypass duct (Ref. Chapter 72-70-01). |
| (3) | Remove the 12 screws (2) . |
| (4) | Remove the
exhaust cone (3)
.
NOTE: The emergency fuel shut-off valve upper mechanism can be inspected without disassembly.
|
| (1) | Visually inspect the rod mechanism. |
| (2) | Remove the cotter pin, the washer and the pin attaching the bellcrank to the cable on the bottom of the exhaust case. |
| (3) | Carefully remove the cable from the fuel shut-off valve (Ref. View A) without disturbing the nuts, and the position of the control lever. |
| (4) | Inspect the bellcrank on the bottom of the exhaust case for condition. Clean as required. |
| (5) | Inspect the shut-off cable as follows:
|
| (9) | Pin and lever:
|
| (11) | Re-set the fuel shut-off valve (Ref. Para. , ). |
| (1) | Apply a thin film of anti-seize compound (PWC06-009) to the threads of the screws (2). |
| (2) | Align the holes and install the exhaust cone (3) on the exhaust case flange (4). |
| (3) | Install the screws (2) and tighten 18 to 22 lb.in. (2-2.4 Nm). |
| (4) | Instal the lower rear inner bypass duct (Ref. Chapter 72-70-01). |
| (5) | Install the rear outer bypass duct (Ref. Chapter 72-70-01). |
| (6) | Install the aft body of the nacelle (Ref. AMM). |
| (7) | Do engine ground checks 1, 2 and 3 (Ref. Chapter 71-00-00). |
| Item No. | Name |
|---|---|
| PWC03-001 | Oil, Engine Lubricating |
| Tool No. | Name |
|---|---|
| PW58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Select maintenance test discrete ON before HMU removal (Ref. Aircraft Maintenance Manual). |
| (2) | Provide drain tray under engine to collect fuel. |
| (3) | Remove airframe fuel inlet connection from HMU (Ref. Aircraft Maintenance Manual). |
| (4) | Remove wiring harness connectors P15, P16, P17 and P35 (8, 9, 7 and 10). |
| (5) | Remove all fuel pressure and bypass tubes (Ref. 73-10-01). |
| (6) | Pre-SB25290: Remove fuel pump and motive flow valve from the HMU (Ref. 73-10-02) and Para. If the HMU is to be replaced, install a blanking cover on the valve mounting port on the HMU and pack in the appropriate shipping case. |
| (7) | Post-SB25290: Do not remove the fuel pump and/or the motive flow valve from the HMU. |
| (8) | Post-SB25290 (Ref. Fig. ):
|
| (12) | Plug/cap all exposed openings and electrical connections. |
| (13) | Remove lockwire, if installed, and loosen flange clamp (3) by removing nut (4). |
| (14) | Remove HMU from mounting face of AC generator (2) and discard preformed packings (5) . |
| (15) | Remove and discard the preformed packing (11) from the fuel pump driveshaft (12) (Ref. View C). |
| (1) | Pre-SB25290:
|
| (5) | Post-SB25290: The fuel pump and motive flow valve are integral with the HMU. Installation is not required. |
| (6) | Post-SB25290 (Ref. Fig. ) :
|
| (9) | Lubricate new preformed packing (5) with engine oil (PWC03-001) and install on HMU. |
| (10) | Lubricate a new preformed packing (11) with engine oil (PWC03-001) and install on fuel pump driveshaft (12) (Ref. View C). |
| (11) | Align splined shaft of fuel pump (if installed) with shaft in accessory gearbox, and dowel pin on HMU with hole in mating face of AC generator and install HMU. |
| (12) | Install flange clamp (3) with nut (4). Make sure clamp is oriented correctly (Ref. View A-A). Torque clamp nut (4) 32 to 36 lb.in. (3.5-4.1 Nm) and gently tap around circumference of clamp to make sure proper seating. Final torque nut (4) 50 to 60 lb.in. (5.7-6.8 Nm). |
| (13) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (14) | Install wiring harness connectors P15, P16, P17 and P35 (8, 9, 7 and 10). Tighten
the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (17) | Install fuel pressure and bypass tubes (Ref. 73-10-01), except do not connect primary and secondary fuel supply tubes to fuel dump valve. |
| (18) | Perform depreservation procedure (Ref. 72-00-00, SERVICING) to purge HMU of preserving fluid. |
| (19) | Restore electrical power to appropriate system and reset EEC circuit breaker to ON. |
| (20) | Select maintenance test discrete OFF. |
| (21) | Refer to Chapter 71-00-00, for checks following installation of HMU. |
| (1) | Refer to 72-60-01 for Removal/Installation of AC Generator (PMA). |
| (1) | Remove three bolts (1) , three washers (2) and remove motive flow valve (3) from the HMU (5) . Remove and discard two preformed packings (4) from the valve (3). |
| (1) | If the motive flow valve is being installed to a replacement HMU, remove the blanking (shipping) cover of the valve mounting port from the HMU. |
| (2) | Install two new preformed packings (4) to the motive flow valve (3) and install valve on mounting port on the HMU (5) . Attach valve with three washers (2) and three bolts (1) . Torque 32 to 36 lb.in. (3.5-4.1 Nm). |
| Item No. | Name |
|---|---|
| PWC05-089 | Lockwire |
| PWC09-003 | Compound, Sealing, Silicone |
| PWC09-008 | Silicone Sealant |
| PWC09-008A | Silicone Sealant |
| PWC11-027 | Solvent, Petroleum |
| Tool No. | Name |
|---|---|
| PWC58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | If an EEC is removed because of suspected malfunctioning, complete the EEC return sheet (Ref. Fig. ) and return it with the EEC. |
| (2) | Select maintenance test discrete ON before EEC removal (Ref. Aircraft Maintenance Manual). |
| (3) | Disconnect engine electrical connectors P1, P3 and P4 (12, 11 and 10) from EEC (1) . Disconnect airframe electrical connectors P2, P5. Check connectors for moisture. If necessary, dry connectors with suitable heat gun. |
| (4) | Remove coupling nut of tube assembly (22) from tube assembly (4) and disengage loop clamp (2) . Remove coupling nut (5) from the EEC. |
| (5) | Remove two bolts (6) and nuts (8) and (9) and disengage harness loop clamp from the EEC bracket. |
| (6) | Plug/cap all openings. |
| (7) | Remove nut (16) , and disengage bracket (18) from the EEC. Remove one end of strap (19) from EEC ground mounting point. |
| (8) | Support EEC and remove two lower bolts (20) and washers (21). Remove two upper bolts (20) and washers (21). Remove EEC from engine. |
| (1) | Position the EEC to the four points on the mounting bracket with four washers (21) and four bolts (20). Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Clean ground terminal and adjacent area with solvent (PWC11-027). |
| (3) | Install bracket (18) and the strap lug on the ground stud on the EEC with nut (16) . |
| (4) | Install rubber cushion (14) in loop clamp (13) and secure with bolt (17) and nut (15) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (5) | Torque nut (16) on ground terminal stud 32 to 36 lb.in. (3.6-4.0 Nm). Apply coat of silicone sealant (PWC09-008) or (PWC09-008A) to ground terminal. |
| (6) | Put tube assembly (4) and install coupling nut (5) to the mating tube on the EEC. Tighten coupling nut with your hand. |
| (7) | Install coupling nut of tube assembly (22) to tube assembly (4) and tighten nut with your hand. Torque 90 to 100 lb.in. (10.2-11.3 Nm) and lockwire (PWC05-089). |
| (8) | Install l loop clamp (2) and bolt (3) . Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (9) | Torque coupling nut (5) 42 to 49 lb.in. (4.7-5.5 Nm) and lockwire (PWC05-089). |
| (10) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (11) |
Remove protective caps/plugs and connect P1 and P4 connectors (12 and 10) to EEC.
Connect trim plug P3 (11). Connect airframe electrical connectors J2 and J5. Tighten
the connector using one of the following methods:
NOTE: For aircraft with Data Transmission Unit (DTU) installed, make sure to pull the
DTU circuit breaker on the overhead cockpit panel.
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lbf.in (11.3 Nm). DO NOT USE
STEEL JAWED PLIERS TO TIGHTEN CONNECTORS.
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lbf.in. (11.3 Nm).
|
| (14) | Set maintenance test discrete to “ON” (MAINT) (Ref. AMM). |
| (15) | Set proximity system breaker to "ON" to activate WOW system. |
| (16) | Set TLA to CUT-OFF and make sure that all thrust lever microswitch breakers are "ON". |
| (17) | Set circuit breaker FADEC Channel A and B to “ON”. |
| (18) | After 15 seconds, set circuit breaker FADEC Channel A and B to “OFF”. |
| (19) | After 15 seconds, set circuit breaker FADEC Channel A to "ON". |
| (20) | After 15 seconds, set circuit breaker FADEC Channel B to "ON". |
| (21) | Make sure that no EEC fault lamps are "ON". If fault lamps are "ON", refer to 72-00-00, FAULT ISOLATION. |
| (22) | After 15 seconds, set maintenance discrete OFF (NORMAL) after EEC installation and before engine operations (Ref. AMM). |
| (23) | After 15 seconds, Refer to Chapter 71-00-00, for checks following installation of EEC. |
| (1) | Remove four cap screws (16) and multiple self-locking nut (14) . |
| (2) | Remove N1 speed trim box (15) . Identify and place in clean plastic bag. |
| (1) | Position N1 speed trim box (15) ) in EEC mounting bracket (9) . |
| (2) | Secure trim box using four cap screws (16) and multiple self-locking nut (14) . |
| (3) | Torque screws (16) 6 to 7 lb.in. (0.7-0.8 Nm). |
| (1) | Remove two nuts (1) , washer (2) , bolt (3) and remove bracket (4) . |
| (2) | Remove two bolts (10) and two washers (11) and remove bracket (6) . |
| (3) | Remove two nuts (20) , two bolts (19) and remove bracket (18) . |
| (4) | Remove two bolts (8) and washers (7) securing lower electrical bracket assembly (9) to bracket (5) on Flange B. |
| (5) | Support lower electrical bracket assembly (9) and remove two nuts (12) , washers (13) and two bolts (17) . Remove lower electrical bracket assembly (9) from engine. |
| (1) | Remove the two bolts (26), the two washers (25) and the lower EEC mount bracket assembly (24). |
| (2) | Remove the two nuts (32), the two washers (31) and the lower rear mount bracket (30). |
| (3) | Remove the two nuts (1), the bolt (3), the washers (2), the two spacers (28) and the upper rear support bracket (29). |
| (4) | Remove the two bolts (10) and the upper front support bracket (23). |
| (5) | Remove the two nuts (12), the two washers (13), the two bolts (17) and the lower front mount bracket (27). |
| (6) | Remove the two nuts (20), the two washers (22), the two spacers (21), the two bolts (19) and the upper front mount bracket (18). |
| (1) | Cracks through the upper and lower strengthening lip, at the locations shown, at either end, are acceptable up to 0.250 inch (6.35 mm) long. Do not stop drill the crack(s). |
| (1) | Install bracket (18) on Flange A of fan case at Location A and secure with two bolts (19) and nuts (20) . Torque nuts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Install support bracket (6) on bracket (18) and secure with two bolts (10) and washers (11). Torque bolts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (3) | Install bracket (4) on Flange B and secure with one bolt (3) , washer (2) and two nuts (1) . Torque nuts 54 to 60 lb.in. (6.0-7.0 Nm). |
| (4) | Install lower electrical bracket assembly (9) to rear side of Flange A and to lower rear support bracket assembly (5) . Secure bracket (9) to Flange A at Locations B with two bolts (17) , washers (13) and nuts (12) , and to bracket (5) with four washers (7) and bolts (8) . Torque nuts (12) and bolts (8) 36 to 40 lb.in. (4.0-4.6 Nm). |
| (1) | Lubricate threads of the two bolts (19) with engine oil (PWC03-001). |
| (2) | Install the upper front mount bracket (18) on flange A of the fan case with the two
spacers (21), the two bolts (19), the two washers (22) and the two nuts (20). Torque
bolts 36 to 40 lbf.in. (4.1-4.5 Nm).
NOTE: Spacers must be installed between the front flange and the bracket.
|
| (3) | Apply a thin coat of silicone grease (PWC09-003) on the two washers (13) for ease of assembly. |
| (4) | Lubricate threads of the two bolts (17) with engine oil (PWC03-001). Install the lower front mount bracket (27) on flange A of the fan case with the two bolts (17), the two washers (13) and the two nuts (12). Torque bolts 36 to 40 lbf.in. (4.1-4.5 Nm). |
| (5) | Lubricate threads of the two bolts (10) with engine oil (PWC03-001). |
| (6) | Install the upper front support bracket (23) on the bracket (18) with the two bolts (10). Torque bolts 36 to 40 lbf.in. (4.1-4.5 Nm). |
| (7) | Install the upper rear support bracket (29) with the two spacers (28), the bolt (3),
the washer (2) and the two nuts (1) on the flange B.
NOTE: Washer must be installed below the bolt head.
|
| (8) | Torque the bolt (3) 62 to 72 lbf.in. (7.0-8.1 Nm) dry. |
| (9) | Torque the nut (1) on the stud 54 to 60 lbf.in. (6.1-6.8 Nm) dry. |
| (10) | Install the lower rear mount bracket (30) with the two washers (31) and the two nuts
(31). Torque nuts 54 to 60 lbf.in. (6.1-6.8 Nm) dry.
NOTE: Washers must be installed below the nuts.
|
| (11) | Lubricate threads of the two bolts (26) with engine oil (PWC03-001). |
| (12) | Install the lower EEC mount bracket assembly (24) to the rear side of flange A and to the lower rear mount bracket (30) with the two bolts (26) and the two washers (25). Torque bolts 36 to 40 lbf.in. (4.1-4.5 Nm). |
| (1) | Remove bolt (17) and nut (15) and separate clamp (13) and rubber cushions (14) from bracket (18) and ground strap (19) . |
| (2) | Remove nut (16) and bracket (18) and remove strap end from EEC ground terminal. |
| (3) | Remove strap end from Flange A:
|
| (1) | Clean shaded area (a), both lugs of ground strap and ground studs with solvent (PWC11-027) to ensure clean ground contact. |
| (2) | Install strap end to Flange A:
|
| (4) | Install strap end to EEC ground terminal with nut (16) . Tighten 36 to 40 lb.in. (4.1-4.5 Nm). |
| (5) | Install cushions (14) and loop clamp (13) on strap (19) to bracket (18) with bolt (17) and nut (15) . Tighten 36 to 40 lb.in. (4.1-4.5 Nm). |
| (6) | Measure the torque of nuts (15, 16 and 26). Make sure that the torque is correct. |
| (7) | Apply coat of silicone sealant (PWC09-008) or (PWC09-008A) on ground terminals and area a (Ref. Fig. ). |
| (1) | Record the class of the trim plug to be removed. The new plug must be the same class for T4.5 and N1 trim. |
| (2) | Remove bolt (1) from retaining strap. |
| (3) | Remove trim plug (2) . |
| (4) | Install protective cap on EEC connector. |
| (1) | Remove protective cap. |
| (2) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (3) |
Install
trim plug (2)
on EEC. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lbf.in (11.3 Nm). DO NOT USE
STEEL JAWED PLIERS TO TIGHTEN CONNECTORS.
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lbf.in. (11.3 Nm).
|
| (6) | Install
bolt (1)
and torque 36 to 40 lbf.in. (4.1 - 4.5 Nm).
NOTE: For aircraft with Data Transmission Unit (DTU) installed, make sure to pull the
DTU circuit breaker on the overhead cockpit panel.
|
| (7) | Set maintenance switch (LH) or (RH) test discrete to MAINT (Ref. Aircraft Maintenance
Manual).
NOTE: Switch located in the tail of the aircraft (Half equipment bay).
|
| (8) | Select airframe 28 VDC power ON (15 Sec). |
| (9) | Select airframe 28 VDC power OFF. |
| (10) | Return maintenance switch (LH) or (RH) test discrete to NORMAL. |
| (11) | Select airframe 28 VDC power ON.
NOTE: This procedure could required to be performed several times (Maximum three times)
to make sure EEC read the proper trim values.
|
| (12) | Make sure no EEC fault lamps are on. |
| (13) | If fault lamps are on, refer to 72-00-00, FAULT ISOLATION. |
| (14) | Do a Check No. 2 - Engine Start, followed by a Check No. 3 - Engine Shutdown (Ref. Chapter 71-00-00, ADJUSTMENT/TEST). |
| Tool No. | Name |
|---|---|
| PW58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jaw Pliers |
| PWC90058 | Tie Cable Tool |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Disconnect connectors P22 and P23. Check connectors for moisture. If necessary, dry with suitable heat gun. |
| (3) | Remove nuts (3) , bolts (2) and loop clamps (4) , fourteen places (Ref. View A, B, C, O, R and V). |
| (4) | Remove nut (3) , bolt (2) and loop clamp (5) from adjacent bracket (Ref. View D). |
| (5) | Remove nut (3) , bolt (2) and loop clamp (5) from adjacent loop clamp (Ref. View E). |
| (6) | Remove nuts (3) , bolts (2) and loop clamps (5) from adjacent tube bracket (Ref. View N). |
| (7) | Remove eight screws (14) , washers (16) and two multiple nut plates (15) securing connectors J6 and J7 to mounting bracket. Remove connectors J6 and J7 (Ref. View F). |
| (8) | Remove nut (3) , bolt (2) , loop clamp (5) , spacer (19) and loop clamp (13) (Ref. View G). |
| (9) | Remove nut (3) , bolt (2) , and loop clamp (7) from adjacent bracket (Ref. View H). |
| (10) | Remove nut (3) , bolt (2) , and loop clamp (6) from adjacent bracket (Ref. View I). |
| (11) | Remove nuts (3) , bolts (2) , and loop clamps (7) , (8) and (9) from adjacent brackets (Ref. View J). |
| (12) | Remove nut (3) , bolt (2) , and loop clamps (11 and 22) (Ref. View K). |
| (13) | Remove nut (3), bolt (2), and loop clamp (12) from bracket (17) (Ref. View L). |
| (14) | Remove nut (3) , bolts (2) , and loop clamp (4) from adjacent bracket (Ref. View M). |
| (15) | Remove nuts (3), bolts (2), and loop clamps (20) and (21) from adjacent bracket (Ref. View P). |
| (16) | Remove nut (3) , bolts (2) , and loop clamp (10) from adjacent bracket (Ref. View Q). |
| (17) | Remove nuts (3) , bolts (2) and loop clamps (9) from adjacent brackets, two places (Ref. View S and U). |
| (18) | Remove nut (3) , bolt (2) and loop clamp (10) from bracket (18) (Ref. View T). |
| (19) | Disconnect connectors P1 and P4 from EEC. Disconnect P31 from trim box. Remove any other associated loop clamps, bolt and nuts. |
| (20) | Disconnect P36 from the EDU. |
| (21) | Disconnect connectors P27, P28, P29 and P39. |
| (22) | Disconnect connectors P15, P16, P17, P34 and P35. |
| (23) | Disconnect connectors P11 and P12. |
| (24) | Remove connectors P9, P10 and P30. |
| (25) | Check all connectors for moisture. If necessary, dry with suitable heat gun. |
| (26) | Check that all associated bolts, nuts and loop clamps are removed, and remove wiring harness (1) from engine. |
| (27) | Place wiring harness and attaching hardware in sealable plastic bags and tag with engine model, serial number, wiring harness part number and date of storage. |
| (1) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (2) | Position wiring harness on intermediate case and connect connectors P22 and P23 to
receptacles at front of intermediate case. Tighten the connector using one of the
following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (5) | Install loop clamps (4) on wiring harness (1) and fasten to brackets with bolts (2) and nuts (3) , nine places (Ref. View A, C, O, R and V). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Install loop clamps (4) on wiring harness and fasten to oil tube brackets with bolts (2) , four places (Ref. View B). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Position connectors J6 and J7 on electrical mounting bracket and secure with eight washers (16), eight screws (14) and two nut plates (15) (Ref. View F). Torque screws 7 to 8 lb.in. (0.8-1.0 Nm). |
| (8) | Install connectors P1 and P4 to EEC. Install connector P31 to trim box. Torque connectors
P1, P4 with pliers (PWC90012). Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (11) | Install
loop clamp (5)
, on wiring harness, and fasten to adjacent bracket with
bolt (2)
and
nut (3)
. Torque nut 36 to 40 lb.in. (4.0-4.6 Nm).
NOTE: The direction of the bolt is determined by the incorporation of SB25329 (Ref. View
D).
|
| (12) | Install loop clamp (5) on wiring harness, and fasten to adjacent loop clamp with bolt (2) and nut (3) (Ref. View E). Torque nut 36 to 40 lb.in. (4.0-4.6 Nm). |
| (13) | Install loop clamps (5) and (13 ) on wiring harness, and fasten together with bolt (2) , spacer (19) between loop clamps, and nut (3) (Ref. View G). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (14) | Install connectors P15, P16, P17 and P35 to HMU (Ref. View W). Tighten the connector
using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (17) | Position loop clamp (7) on wiring harness and secure to J bracket with bolt (2) and nut (3) (Ref. View H). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (18) | Position loop clamp (6) on wiring harness and fasten to bracket with bolt (2) and nuts (3) (Ref. View I). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (19) | Position loop clamps (7) , (8) and (9) on wiring harness and fasten to brackets with bolts (2) and nuts (3) (Ref. View J). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (20) | Install connectors P11 and P12 to their respective receptacles. Tighten the connector
using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (23) | Position loop clamp (11) on wiring harness and fasten to oil tube loop clamp (22) with bolt (2) and nuts (3) (Ref. View K) . Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (24) | Position loop clamp (12) on wiring harness and fasten to bracket (17) with bolt (2) and nut (3) (Ref. View L). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (25) | Install connectors P27, P28 and P29. Tighten the connector using one of the following
methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (28) | Position loop clamp (10) on wiring harness and fasten to respective bracket with bolts (2) and nuts (3) (Ref. View Q). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (29) | Position loop clamps (21) and (20) on wiring harness and fasten to respective bracket with bolts (2) and nuts (3) (Ref. View P). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (30) | Install connectors P9, P10 and P30. Tighten the connector using one of the following
methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (33) | Install connector P34 to start fuel and dump valve. Tighten the connector using one
of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (36) | Position loop clamps (9) on wiring harness and fasten to respective brackets with bolts (2) and nuts (3) , two places (Ref. View S and U). Torque nuts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (37) | Restore electrical power to the appropriate system and reset EEC circuit breaker to ON. |
| (38) | Select maintenance test discrete OFF (Ref. Aircraft Maintenance Manual). |
| (39) | Refer to Chapter 71-00-00 for checks following installation of wiring harness. |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Remove bolt (2) , nut (3) and loop clamp (20) from EDU bracket (18) (Ref. Sheet 6, View F). |
| (3) | Remove bolt (27) from the N2 speed sensor and remove loop clamp (7) (Ref. Sheet 5, View G). |
| (4) | Remove bolts (2) and nuts (3) in three places. Remove two loop clamps (7) and one loop clamp (20) from brackets (21) (Ref. Sheet 6, View I). |
| (5) | Remove connector P36 from the EDU. |
| (6) | Remove bolt (2) , nut (3) , clamp (32) and grommet (33) from AGB bracket (Ref. Sheet 8). |
| (7) | Remove bolt (2), nut (3) and loop clamp (11) above P12 from the oil tube loop clamp (13) (Ref. Sheet 8). |
| (8) | Remove bolt (2), nut (3) and loop clamp (16) near P34, from the fuel pressure tube loop clamp (13) (Ref. Sheet 6, View H). |
| (9) | Remove bolt (2) , nut (3) and loop clamp (8) from the heat exchanger bracket (18) (Ref. Sheet 2). |
| (10) | Remove bolt (2) , nut (3) and loop clamp (10) from bracket (17) (Ref. Sheet 3, Detail C). |
| (11) | Remove bolt (25) , spacer (26) , nut (3) and loop clamp (7) from the fuel bypass tube loop clamp (13) (Ref. Sheet 4). |
| (12) | Remove bolt (2) , nut (3) and loop clamp (11) from AGB bracket (Ref. Sheet 8). |
| (13) | Remove bolt (2) , nut (3) and loop clamp (16) from bracket (29) (Ref. Sheet 7, View J). |
| (14) | Remove bolts (2) and loop clamps (4) below P30 from the bypass duct brackets in three places (Ref. Sheet 5). |
| (15) | Remove bolt (2) , nut (3) and loop clamp (12) next to the HMU from the harness support (Ref. Sheet 4). |
| (16) | Remove bolts (2) , nuts (3) and loop clamps (5) and (7) from the harness support bracket (Ref. Sheet 3, Detail D). |
| (17) | Remove bolt (2) , nut (3) and loop clamp (4) below P29 from the harness support (Ref. Sheet 2). |
| (18) | Remove bolt (2) , nut (3) and loop clamp (6) below P27&28 from the harness support (Ref. Sheet 2). |
| (19) | Remove bolt (2), nut (3) and loop clamp (7) from the EEC mounting bracket (Ref. Sheet 1, View A, Detail K). |
| (20) | Remove bolt (2) , nut (3) and loop clamp (5) from the oil tube bracket (Ref. Sheet 1, View A). |
| (21) | Remove bolts (2) and loop clamps (4) from the oil tube brackets, in four places (Ref. Sheet 1, View A). |
| (22) | Remove bolts (2) , nuts (3) and loop clamps (6) and (4) behind P22&23 from the harness support bracket in two places (Ref. Sheet 1, View A). |
| (23) | Remove connectors P22 and P23 from the P1/T1 sensors (Ref. Sheet 1, View A). |
| (24) | Remove eight screws (14) , two nut plates (15) and connectors J6 and J7 from the mounting bracket (Ref. Sheet 1, View B). |
| (25) | Remove bolt (24) , spacer (19) , nut (3) and loop clamp (9) from the oil pressure tube loop clamp (11) (Ref. Sheet 3, Detail B). |
| (26) | Remove bolt (2) , nut (3) and loop clamp (9) from the P1 tube bracket (Ref. Sheet 2). |
| (27) | Remove connectors P1 and P4 from the EEC. |
| (28) | Remove connectors P9, P10, P11, P12, P34, P35, P17, P16, P15, P28, P27, P39 and P29. |
| (29) | Check all connectors for moisture. If necessary, dry with suitable heat gun. |
| (30) | Check that all associated bolts, nuts and loop clamps are removed, and remove wiring harness (1) from engine. |
| (31) | Place wiring harness and attaching hardware in sealable plastic bags and tag with engine model, serial number, wiring harness part number and date of storage. |
| (1) | Install (or replace if necessary) insulation tape (ST6333-01) on the harness as follows:
CAUTION: MAKE SURE TO TIGHTEN EACH TIE CABLE UNTIL THE HARNESS IS IN POSITION AGAINST THE
CABLE TIE MOUNT.
|
| (9) | Install wiring harness on left side of engine and connect connector P29. Tighten the
connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (12) | Connect connector P39. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (15) | Connect connectors P27 and P28. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (18) | Connect connectors P15, P16, P17, P35 and P34. Tighten the connector using one of
the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (21) | Install wiring harness on right side and connect connector P30. Tighten the connector
using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (24) | Connect connectors P10 and P9. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (27) | Connect connectors P11 and P12. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (30) | Connect connectors P1 and P4 to the EEC. Tighten the connector using one of the following
methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (33) | Install loop clamp (9) , on wiring harness, and attach to P1 tube bracket with bolt (2) and nut (3) (Ref. Sheet 2). Torque nut 36 to 40 lb.in. (4.0-4.6 Nm). |
| (34) | Install loop clamp (9) on wiring harness, and attach to oil pressure tube loop clamp (11) with bolt (24) , spacer (19) and nut (3) (Ref. Sheet 3, Detail B). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (35) | With the master keyways at the upper outboard side, install connectors J6 and J7 in the mounting bracket and attach with eight screws (14) , and two nut plates (15) ) (Ref. Sheet 1, View B). Torque screws 6 to 7 lb.in. (0.68-0.79 Nm). |
| (36) | Make sure the front of connectors P22 and P23 can extend 3 inches forward of the fan
case to reach the P1/T1 sensors. If the sensors are already installed, connect connectors
P22 and P23 (Ref. Sheet 1, View A). Tighten the connector using one of the following
methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (39) | Install loop clamps (6) and (4) on wiring harness behind P22&23 and attach to harness support bracket with bolts (2) and nuts (3) in two places (Ref. Sheet 1, View A). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (40) | Install loop clamps (4) on wiring harness and attach to oil tube brackets with bolts (2) , in four places (Ref. Sheet 1, View A). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (41) | Install loop clamp (5) on wiring harness, and attach to oil tube bracket with bolt (2) and nut (3) (Ref. Sheet 1, View A). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (42) | Install
loop clamp (7)
on wiring harness, and attach to top hole of EEC mounting bracket with bolt (2) and
nut (3) . Torque nut 36 to 40 lb.in. (4.0-4.6 Nm).
NOTE: The direction of the bolt is determined by the incorporation of SB25329 (Ref. Sheet
1, View A, Detail K).
|
| (43) | Install loop clamp (6) on wiring harness below P27&28 and attach to harness support with bolt (2) and nut (3) (Ref. Sheet 2). Torque nut 36 to 40 lb.in. (4.0-4.6 Nm). |
| (44) | Install loop clamp (4) on wiring harness below P29 and attach to harness support with bolt (2) and nut (3) (Ref. Sheet 2). Torque nut 36 to 40 lb.in. (4.0-4.6 Nm). |
| (45) | Install loop clamps (5) and (7) , on wiring harness, and attach to harness support bracket with bolts (2) and nuts (3) (Ref. Sheet 3, Detail D). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (46) | Install loop clamp (12) on wiring harness next to HMU and attach to harness support with bolt (2) and nut (3) (Ref. Sheet 4). Torque nut 36 to 40 lb.in. (4.0-4.6 Nm). |
| (47) | Install loop clamps (4) on wiring harness below P30 and attach to bypass duct brackets with bolts (2) , in three places (Ref. Sheet 5). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (48) | If not already installed, install bracket (29) on lower bypass duct flange, and attach with bolt (31), washer (30) and nut (3) (Ref. Sheet 7, View J). Torque bolt 27 to 30 lb.in. (3.05-3.39 Nm). |
| (49) | If not already installed, install two bolts (31), washers (30) and nuts (3) (Ref. Sheet 7, View J). Torque bolts 27 to 30 lb.in. (3.05-3.39 Nm). |
| (50) | Install loop clamp (16) on wiring harness and attach to bracket (29) with bolt (2) and nut (3) (Ref. Sheet 7, View J). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (51) | Install loop clamp (11) on wiring harness and attach to AGB bracket with bolt (2) and nut (3) (Ref. Sheet 8). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (52) | Install loop clamp (7) on wiring harness and attach to fuel bypass tube loop clamp (13) with bolt (25) , spacer (26) and nut (3) (Ref. Sheet 4). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (53) | Install loop clamp (10) on wiring harness and attach to bracket (17) with bolt (2) and nut (3) (Ref. Sheet 3, Detail C). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (54) | Install loop clamp (8) on wiring harness and attach to heat exchanger bracket (18) with bolt (2) and nut (3) (Ref. Sheet 2). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (55) | Install loop clamp (16) on wiring harness near P34, and attach to fuel pressure tube loop clamp (13) with bolt (2) and nut (3) (Ref. Sheet 6, View H). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (56) | Install loop clamp (11) on wiring harness above P12 and attach to oil tube loop clamp (13) with bolt (2) and nut (3) (Ref. Sheet 8). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (57) | Install grommet (33) and clamp (32) on wiring harness, and attach to AGB bracket with bolt (2) and nut (3) (Ref. Sheet 8). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (58) | Connect connector P36 to the EDU. Tighten the connector using one of the following
methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (61) | If not already installed, install two fire detection brackets (28) and three brackets (21) to the fan case rear flange (Ref. Sheet 6, View I). Attach with three nuts (34) and torque 54 to 60 lb.in. (6.1-6.78 Nm). |
| (62) | Install two loop clamps (7) and one loop clamp (20) on wiring harness, and attach to brackets (21) in three places with bolts (2) and nuts (3) (Ref. Sheet 6, View I). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (63) | Remove the lower bolt (27) from N2 speed sensor. Install loop clamp (7) on wiring harness, and attach to N2 speed sensor with bolt (27) (Ref. Sheet 5, View G). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (64) | If not already installed, install bracket (18) on EDU mounting bracket, and attach with bolt (2) (Ref. Sheet 6, View F). Torque bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (65) | Install loop clamp (20) on wiring harness, and attach to bracket (18) with bolt (2) and nut (3) (Ref. Sheet 6, View F). Torque nut 36 to 40 lb.in. (4.0-4.6 Nm). |
| (66) | Restore electrical power to the appropriate system and reset EEC circuit breaker to ON. |
| (67) | Select maintenance test discrete OFF (Ref. Aircraft Maintenance Manual). |
| (68) | Refer to Chapter 71-00-00 for checks following installation of wiring harness. |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Disconnect rear core wiring harness N1 OUT connectors (22) from N1/T4.5 terminal box (33) (Ref. 77-20-01). |
| (3) | Remove two bolts (6) (Ref. View D) and two self-locking nuts (2) from bracket (1). Remove loop clamps (3) , (4) and (5) from wiring harness (22). |
| (4) | Remove two self-locking nuts (25) and (27) (Ref. View B), two bolts (29) and (32) and bracket (31) . Remove loop clamps (24) , (26) , (28) and (30) from rear core wiring harness (22). |
| (5) | Remove self-locking nut (8) (Ref. View D) and bolt (13) from bracket (7). Remove loop clamps (9) , (11) and (12) from wiring harness (22). |
| (6) | Remove eight screws (18) (Ref. View A) or cap screws, eight washers (17) and two nut plates (14) from two terminal connectors (15). Remove two gaskets (16) . |
| (7) | Remove two bolts (19) and remove wiring harness (22) from engine. |
| (8) | Remove two bolts (20) and two self-locking nuts (35) securing bracket (21) to wiring harness. |
| (9) | Place protective covers on all connectors and receptacles. |
| (1) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (2) | Secure bracket assembly (21) to rear core harness (22) using two bolts (20) and two self-locking nuts (35) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (3) | Install two gaskets (16) (Ref. View A) on two terminal connectors (15) and position wiring harness on engine. Secure wiring harness (22) to rear support ring using two bolts (19) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (4) | Secure two terminal connectors (15) to lower bypass duct using eight washers (17) and eight cap screws (18) . Torque 6.0 to 7.0 lb.in. (0.6-0.8 Nm). |
| (5) | Install loop clamps (9) , (11) and (12) (Ref. View C) on wiring harness and clamp (10) (part of T4.5 wiring harness). Secure loop clamps to bracket (7) and clamp (10) (part of T4.5 wiring harness) using bolt (13) and self-locking nut (8) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Secure loop clamp (24) (Ref. View B) and bracket (31) to bracket (23) using bolt (32) and self-locking nut (27) . Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (7) | Install loop clamp (26) , (28) and (30) on wiring harness and secure to bracket (31) using bolt (29) and self-locking nut (25) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Position loop clamp (3) , (4) and (5) (Ref. View D) on wiring harness and secure to bracket (1) using bolts (6) and self-locking nuts (2) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (9) | Install rear core wiring harness (22) in N1/T4.5 terminal box (33) (Ref. 77-20-01). |
| (10) | Restore electrical power to appropriate system and reset EEC circuit breaker to ON. |
| (11) | Select maintenance discrete OFF. |
| (12) | Pull EEC circuit breaker to OFF. |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Remove upper (outer and inner) bypass ducts (Ref. 72-70-01). |
| (3) | Remove top P2.8 supply tube (Ref. 75-30-01). |
| (4) | Remove bolt (2) and loop clamp (3) (Ref. Detail A). |
| (5) | Pre-SB25378: Remove two screws (4) , two washers (5) and nut plate (6) (Ref. View B). Remove J29 connector (7) from left outer bypass duct and remove gasket (8) . |
| (6) | Post-SB25378: Remove four screws (4), four washers (5) and nut plate (6) (Ref. View B). Remove J29 connector (7) from left outer bypass duct and remove gasket (8). |
| (7) | Remove three self-locking nuts (9) , three bolts (10) and three loop clamps (11) . |
| (8) | Pre-SB25378: Remove two screws (12) , two washers (13) and nut plate (14) (Ref. View D). Remove J30 connector (15) from right side bypass duct and remove gasket (16) . |
| (9) | Post-SB25378: Remove four screws (12), four washers (13) and nut plate (14) (Ref. View D). Remove J30 connector (15) from right side bypass duct and remove gasket (16). |
| (10) | Remove bolt (17) and loop clamp (18) (Ref. Detail C). |
| (11) | Remove self-locking nut (19) , bolt (20) and loop clamps (21) (Ref. View E). |
| (12) | Remove self-locking nut (22) , spacer (23) , loop clamps (24) and bolt (25) (Ref. View F). |
| (13) | Remove self-locking nut (26) , bolt (27) and loop clamp (28) (Ref. View G). |
| (14) | Remove self-locking nut (29) , bolt (30) and loop clamp (31) from bracket (32) (Ref. View H). |
| (15) | Remove self-locking nut (33) , bolt (34) and loop clamp (35) from P3 tube assembly (36) (Ref. View J). |
| (16) | Remove P connectors (37, 38, 39, 40, 41, 42 and 43) and remove wiring harness (1) . |
| (17) | Put protective covers on all connectors and receptacles. |
| (1) | Apply electrical contact enhancer to all connectors (Ref. Ch. 70-00-00, CLEANING). |
| (2) | Position front core wiring harness (1) on compressor case. |
| (3) | Engage master keyway and install P24 connector (40) and P25 connector (41) on linear
stator vane actuator. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (6) | Engage master keyway and install P18 connector (39) on anti-icing valve. Tighten the
connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (9) | Engage master keyway and install P14 connector (38) and P13 connector (37) on compressor
bleed valve solenoid. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (12) | Engage master keyway and install P37 connector (42) and P38 connector (43) on compressor
start bleed valve solenoid. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (15) | Pre-SB25378: Install gasket (8) on J29 connector (7) and position connector in left lower bypass duct half with master keyway at top center. Attach with nut plate (6) , two washers (5) and two screws (4) (Ref. View B). Torque the screws 6 to 7 lb.in. (0.6-0.8 Nm). |
| (16) | Post-SB25378: Install gasket (8) on J29 connector (7) and position connector in left lower bypass duct half with master keyway at top center. Attach with nut plate (6), four washers (5) and four screws (4) (Ref. View B). Torque the screws 6 to 7 lbf.in. (0.6-0.8 Nm). |
| (17) | Position loop clamp (3) on wiring harness (1) and attach clamp to left side lower fairing with bolt (2) (Ref. Detail A). Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (18) | Position loop clamp (11) on wiring harness (1). Attach clamp to P3 tube assembly (36) with bolt (10) and nut (9) . Torque nut 36 to 40 lb.in. (4.1-4.5 Nm). |
| (19) | Position two loop clamps (11) on wiring harness (1). Attach clamps (11) to flange mounted brackets with two bolts (10) and two self-locking nuts (9). Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (20) | Pre-SB25378 Install gasket (16) on J30 connector (15) and position connector in right lower bypass duct half with master keyway at top center. Attach with nut plate (14) , two washers (13) and two screws (12) (Ref. View D). Torque 6 to 7 lb.in. (0.6-0.8 Nm). |
| (21) | Post-SB25378: Install gasket (16) on J30 connector (15) and position connector in left lower bypass duct half with master keyway at top center. Attach with nut plate (14), four washers (13) and four screws (12) (Ref. View B). Torque the screws 6 to 7 lbf.in. (0.6-0.8 Nm). |
| (22) | Position loop clamp (18) on wiring harness (1). Attach clamp (18) to right lower side fairing with bolt (17) (Ref. Detail C). Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (23) | Position loop clamp (35) on wiring harness (1). Attach clamp to P3 tube assembly (36) with bolt (34) and nut (33) (Ref. View J). Torque nut 36 to 40 lb.in. (4.1-4.5 Nm). |
| (24) | Position loop clamp (31) on wiring harness (1). Attach clamp (31) to bracket (32) with bolt (30) and self-locking nut (29) (Ref. View H). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (25) | Position loop clamp (28) on wiring harness (1). Attach clamp (28) to P3 adapter flange with bolt (27) and self-locking nut (26) (Ref. View G). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (26) | Position loop clamp (24) on wiring harness (1). Attach clamps (24), spacer (23) with bolt (25) and self-locking nut (22) (Ref. View F). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (27) | Position loop clamp (21) on wiring harness (1). Attach clamps (21) to flange mounted bracket with bolt (20) , and self-locking nut (19) (Ref. View E). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (28) | Install upper section of bypass ducts (Ref. Ch. 72-70-01). |
| (29) | Install top P2.8 supply tube (Ref. 75-30-01). |
| (30) | Restore electrical power to appropriate system and reset EEC circuit breaker. |
| (31) | Select maintenance test discrete OFF after wiring harness installation (Ref. Aircraft Maintenance Manual). |
| (32) | Refer to Chapter 71-00-00 for checks following installation of engine wiring harness. |
| (33) | Pull EEC circuit breaker to OFF. |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Remove upper (outer and inner) bypass ducts (Ref. 72-70-01). |
| (3) | Remove top P2.8 supply tube (Ref. 75-30-01). |
| (4) | Remove bolt (2) and loop clamp (3) (Ref. Detail A). |
| (5) | Pre-SB25378: Remove two screws (4) , two washers (5) and nut plate (6) (Ref. View B). Remove J29 connector (7) from left outer bypass duct and remove gasket (8) . |
| (6) | Post-SB25378: Remove four screws (4), four washers (5) and nut plate (6) (Ref. View B). Remove J29 connector (7) from left outer bypass duct and remove gasket (8). |
| (7) | Remove three self-locking nuts (9) , three bolts (10) and three loop clamps (11) . |
| (8) | Pre-SB25378: Remove two screws (12) , two washers (13) and nut plate (14) (Ref. View D). Remove J30 connector (15) from right side bypass duct and remove gasket (16) . |
| (9) | Post-SB25378: Remove four screws (12), four washers (13) and nut plate (14) (Ref. View D). Remove J30 connector (15) from right side bypass duct and remove gasket (16). |
| (10) | Remove bolt (17) and loop clamp (18) (Ref. Detail C). |
| (11) | Remove self-locking nut (19) , bolt (20) , spacer (44) and loop clamps (21) (Ref. View E). |
| (12) | Remove self-locking nut (22) , spacer (23) , loop clamps (24) and bolt (25) (Ref. View F). |
| (13) | Remove self-locking nut (26) , bolt (27) and loop clamps (28) from bracket (45) (Ref. View H). |
| (14) | Remove self-locking nut (29) , bolt (30) and loop clamp (31) from bracket (32) (Ref. View J). |
| (15) | Remove self-locking nut (33) , bolt (34) and loop clamp (35) from P3 tube assembly (36) (Ref. View K). |
| (16) | Remove P connectors (37, 38, 39, 40, 41, 42 and 43) and remove wiring harness (1) . |
| (17) | Place protective covers on all connectors and receptacles. |
| (1) | Apply electrical contact enhancer to all connectors (Ref. Ch. 70-00-00, CLEANING). |
| (2) | Position front core wiring harness (1) on compressor case. |
| (3) | Engage master keyway and install P24 connector (40) and P25 connector (41) on linear
stator vane actuator. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (6) | Engage master keyway and install P18 connector (39) on anti-icing valve. Tighten the
connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (9) | Engage master keyway and install P14 connector (38) and P13 connector (37) on compressor
bleed valve solenoid. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (12) | Engage master keyway and install P37 connector (42) and P38 connector (43) on compressor
start bleed valve solenoid. Tighten the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (15) | Pre-SB25378: Install gasket (8) on J29 connector (7) and position connector in left lower bypass duct half with master keyway at top center. Attach with nut plate (6) , two washers (5) and two screws (4) (Ref. View B). Torque the screws 6 to 7 lb.in. (0.6-0.8 Nm). |
| (16) | Post-SB25378: Install gasket (8) on J29 connector (7) and position connector in left lower bypass duct half with master keyway at top center. Attach with nut plate (6), four washers (5) and four screws (4) (Ref. View B). Torque the screws 6 to 7 lbf.in. (0.6-0.8 Nm). |
| (17) | Position loop clamp (3) on wiring harness (1) and attach clamp to left side lower fairing with bolt (2) (Ref. Detail A). Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (18) | Position loop clamp (11) on wiring harness (1). Attach clamp to P3 tube assembly (36) with bolt (10) and nut (9) . Torque nut 36 to 40 lb.in. (4.1-4.5 Nm). |
| (19) | Position two loop clamps (11) on wiring harness (1). Attach clamps (11) to flange mounted brackets with two bolts (10) and two self-locking nuts (9). Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (20) | Pre-SB25378 Install gasket (16) on J30 connector (15) and position connector in right lower bypass duct half with master keyway at top center. Attach with nut plate (14) , two washers (13) and two screws (12) (Ref. View D). Torque 6 to 7 lb.in. (0.6-0.8 Nm). |
| (21) | Post-SB25378: Install gasket (16) on J30 connector (15) and position connector in left lower bypass duct half with master keyway at top center. Attach with nut plate (14), four washers (13) and four screws (12) (Ref. View B). Torque the screws 6 to 7 lbf.in. (0.6-0.8 Nm). |
| (22) | Position loop clamp (18) on wiring harness (1). Attach clamp (18) to right lower side fairing with bolt (17) (Ref. Detail C). Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (23) | Position loop clamp (35) on wiring harness (1). Attach clamp to P3 tube assembly (36) with bolt (34) and nut (33) (Ref. View J). Torque nut 36 to 40 lb.in. (4.1-4.5 Nm). |
| (24) | Position loop clamp (31) on wiring harness (1). Attach clamps (31) to bracket (32) with bolt (30) and self-locking nut (29) (Ref. View J). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (25) | Position loop clamp (28) on wiring harness (1). Attach clamps (28) to P3 adapter flange mounted bracket with bolt (27) and self-locking nut (26) (Ref. View H). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (26) | Position loop clamp (24) on wiring harness (1). Attach clamps (24), spacer (23) with bolt (25) and self-locking nut (22) (Ref. View F). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (27) | Position loop clamp (21) on wiring harness (1). Attach clamps (21), spacer (44) to flange mounted bracket with bolt (20) and self-locking nut (19) (Ref. View E). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (28) | Install upper section of bypass ducts (Ref. Ch. 72-70-01). |
| (29) | Install top P2.8 supply tube (Ref. 75-30-01). |
| (30) | Restore electrical power to appropriate system and reset EEC circuit breaker. |
| (31) | Select maintenance test discrete OFF after wiring harness installation (Ref. Aircraft Maintenance Manual). |
| (32) | Refer to Chapter 71-00-00 for checks following installation of engine wiring harness. |
| (33) | Pull EEC circuit breaker to OFF. |
| Item No. | Name |
|---|---|
| PWC05-089 | Lockwire |
| PWC06-005 | Lubricant, Fluorocarbon |
| PWC09-001 | Sealant, Silicone Rubber |
| PWC11-005+ | Envirosolv 655 |
| PWC11-012 | Acetone |
| PWC11-014 | Alcohol, Isopropyl |
| PWC11-023+ | Ardrox Leeder 1064K |
| PWC11-025+ | Desoclean 45 |
| (1) | Isolate power from ignition system. |
| (2) | Remove igniter cable assemblies from connectors of ignition exciters. |
| (3) | Remove sealant from bolts (6) at electrical lead (4) and connecting strap (7) . Remove eight bolts (6), three washers (5) and (8) and connecting strap (7). |
| (4) | Pre-SB25378: Remove the bolt (3) and washer (2) from the electrical bracket (1) and remove the electrical bracket (1) from the electrical lead (4). |
| (5) | Post-SB25378: Remove the nut (15) and spacer (16) from electrical lead (4) at the bypass duct. |
| (6) | Remove electrical lead (4) and two ignition exciters (9) from mounting plate (13). |
| (7) | Remove mounting plate (13) if necessary, by removing bolts (10) and washers (11) . |
| (1) | Position mounting plate (13) on bypass duct and secure with four bolts (10) and washers (11) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Position ignition exciters (9) with input connectors towards front of engine on mounting plate and secure with bolts (6) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (3) | Clean contact area of connecting strap (7) with isopropyl alcohol (PWC11-014) and install with bolts (6) and washers (8) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (4) | Pre-SB25378: Clean contact area on ends of lead (4) , bracket (1) and ignition exciter (9) with isopropyl alcohol (PWC11-014). |
| (5) | Post-SB25378: Clean contact area on ends of lead (4) and ignition exciter (9) with isopropyl alcohol (PWC11-014). |
| (6) | Pre-SB25378: Lubricate threads of the two bolts (3) and (6) with engine oil (PWC03-001). Install lead with bolts (3) and (6) and washers (2) and (5) . Torque the bolts 36 to 40 lbf.in. (4.1-4.5 Nm). |
| (7) | Post-SB25378: Lubricate threads of the bolt (6) and nut (15) with engine oil (PWC03-001). Install one end of the lead with the bolt (6) and washer (5) at the ignition exciter and the other end of the lead with nut (15) and spacer (16) at the bypass duct. Torque the bolt (6) and nut (15) 36 to 40 lbf.in. (4.1-4.5 Nm). |
| (8) | Apply a coat of sealant (PWC09-001) to electrical contact areas on connecting strap (7) and lead (4). |
| (9) | Connect ignition cable assemblies to connectors on ignition exciters (Ref. Subpara ). |
| (10) | Reconnect input cable to ignition exciter (Ref. Aircraft Maintenance Manual). |
| (1) | Loosen coupling nuts (24) and disconnect ignition cables (23) from ignition exciters (11) . |
| (2) | Remove nut (10) , spacer (9) and bolt (8) . Remove two loop clamps (7) . |
| (3) | If necessary, remove two nuts (20) , washers (22) , bolt (21) and bracket (19) . |
| (4) | Remove nut (6) , bolt (5) and two clamps (4) . |
| (5) | Remove four bolts (3) , two brackets (2) and two grommets (1) . |
| (6) | Remove screws (17) and fairing (18) to gain access to grommet (13) and remove grommet from stiffener ring of inner bypass duct. |
| (7) | Remove bolt (16) , clamp (15) and cushion (14) . |
| (8) | Post-SB25384: Remove bolt (26), spacer (27) and loop clamp (28). |
| (9) | Loosen coupling nuts (12) and disconnect ignition cables from spark igniters. |
| (1) | Install spark igniters (Ref. Subpara. ). |
| (2) | Connect cable coupling nuts (12) to spark igniters (25) . Torque 240 to 260 lb.in. (27.1-29.4 Nm). |
| (3) | Post-SB25384: Attach the loop clamp (28) to the ignition cable (23) and install with spacer (27) and bolt (26). Torque bolt 36 to 40 lbf.in. (4.1-4.5 Nm). |
| (4) | Install grommet (13) around cables and slide into stiffener of inner bypass duct. |
| (5) | Position cushion (14) and clamp (15) on igniter cables and fasten to fairing with bolt (16) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (6) | Install fairing (18) with screws (17) and torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (7) | Place two grommet halves (1) around cables and press into boss on outer bypass duct. Secure with two brackets (2) and four bolts (3) . Torque 36 to 40 lb.in. (4.1-4.5 Nm) in a star pattern. |
| (8) | Install two loop clamps (4) with bolt (5) and nut (6) . Torque 27 to 30 lb.in. (3.1-3.4 Nm). |
| (9) | Connect cable coupling nuts (24) to ignition exciters. Torque 140 to 160 lb.in. (15.8-18.1 Nm). |
| (10) | Locate bracket (19) on rear flange of lower outer bypass duct, on fifth and sixth holes with two bolt (21) , washers (22) and nuts (20) . Torque 27 to 30 lb.in. (3.1-3.4 Nm). |
| (11) | Install two loop clamps (7) , spacer (9) , bolt (8) and nut (10) . Torque 27 to 30 lb.in. (3.1-3.4 Nm). |
| (1) | Isolate power from ignition system. |
| (2) | Carefully remove coupling nuts (3) of igniter cable assemblies and from spark igniters (2) . |
| (3) | Ground cable electrodes to spark shield to ensure complete electrical discharge. |
| (4) | Unscrew and remove spark igniters (2) and gaskets (1) . |
| (5) | Remove gasket from each spark igniter. |
| (1) | Install gaskets (1) on each spark igniters (2) . |
| (2) | Carefully install spark igniters with gaskets into bosses in combustion chamber outer case at 4 and 5 o'clock positions on engine without using tools, until igniters are seated. |
| (3) | Torque igniters 300 to 360 lb.in. (33.9-40.7 Nm). |
| (1) | Inspect for security, signs of damage and general condition. |
| (2) | Inspect input and output connectors for damage. Check threads for corrosion. |
| (1) | Check for chafing, cuts, abrasions or other damage. |
| (2) | Check for security of installation. |
| (3) | Check operation of cables (Ref. Para. ). |
| (1) | Inspect the external sheath of each igniter at Dia. A for chafing and wear:
|
| (5) | Inspect end face (View B) for:
|
| (11) | Check operation of spark igniters (Ref. Para. ). |
| (1) | Remove all corrosion residue, using a stainless steel wire brush, taking care not to damage gold plating on the terminal pins. |
| (2) | Clean affected surface thoroughly, using a clean, lint-free cloth moistened with isopropyl alcohol (PWC11-014) or acetone (PWC11-012) or ardrox leeder 1064K (PWC11-023+) or desoclean 45 (PWC11-025+) or envirosolv 655 (PWC11-005+). |
| (3) | Apply light film of spray lubricant (PWC06-005) to cleaned areas. |
| (1) | Install a suitable cap over electrode end of igniter to prevent contamination by cleaning fluid. |
| (2) | Clean inside of terminal well with a felt swab soaked in isopropyl alcohol (PWC11-014) or acetone (PWC11-012) or ardrox leeder 1064K (PWC11-023+) or desoclean 45 (PWC11-025+) or envirosolv 655 (PWC11-005+). Do not damage terminal pin during cleaning operation. |
| (3) | Dry using clean, dry, filtered compressed air. |
| (1) | Switch ignition system OFF. |
| (2) | Isolate electrical power from ignition system (Ref. Aircraft Maintenance Manual). |
| (3) | Disconnect one igniter input lead at exciter unit. |
| (4) | Restore electrical power to ignition system (Ref. Aircraft Maintenance Manual). |
| (5) | Switch ignition ON. |
| (6) | Listen for regular frequency snapping sound. Switch ignition OFF. |
| (7) | Reconnect igniter cable to exciter unit and remove igniter cable from other exciter unit. Repeat steps and . |
| (8) | If snapping sound is not heard on either check, replace ignition exciter and repeat steps through . |
| (9) | If snapping sound is not heard on one check only, replace associated spark igniter and/or ignition cable and repeat operation check. If spark igniter still fails, replace ignition exciter. |
| (10) | Repeat steps through . |
| (11) | Restore ignition system to standard operating condition. |
| (12) | Refer to Chapter 71-00-00 for checks following installation of ignition system components. |
| Item No. | Name |
|---|---|
| PWC05-089 | Lockwire |
| (1) | Select maintenance test discrete ON before anti-ice solenoid valve removal (Ref. Aircraft Maintenance Manual). |
| (2) | Remove engine nacelle, sufficient to gain access to engine by-pass duct (Ref. Aircraft Maintenance Manual). |
| (3) | Remove upper portion of by-pass duct (inner and outer) (Ref. 72-70-01). |
| (4) | Remove two bolts (1) securing P3 tube assembly (2) to solenoid valve (3) . |
| (5) | Post-SB25095: Remove nut (14) , bolt (15) and clamp (16) from the bracket (17) . |
| (6) | Remove nut (18) , bolt (19) and clamp (20) from bracket (21). |
| (7) | Remove the lockwire and P3 tube coupling nut (22). Remove P3 tube assembly (2). |
| (8) | Disconnect electrical connector P18 (4) at solenoid valve. |
| (9) | Remove two nuts (5) , bolts (6) and retaining plate (7) . |
| (10) | Slide transfer tube (8) part way into anti-icing tube (9) , remove solenoid valve (3) together with gasket (10) , discard gasket. |
| (11) | Remove transfer tubes (8) and (11) , remove and discard seals (12) . |
| (1) | Install new plain seals (12) on transfer tubes (8) and (11) . Install open end of seals toward open end of tube. |
| (2) | Install retaining ring (13) on tube but do not engage in slot. |
| (3) | Install transfer tube (11). |
| (4) | Slide transfer tube (8) part way into anti-icing tube (9) . |
| (5) | Insert gasket (10) into recess of solenoid valve (3) . |
| (6) | Note position of airflow arrow on solenoid valve (3) and install valve onto transfer tube (11). Slide transfer tube (8) into open end of solenoid valve. |
| (7) | Install retaining plate (7) and secure using two bolts (6) and nuts (5) , torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (8) | Install retaining ring (13) on slot of tube (8). |
| (9) | Install electrical connector P18 (4) onto solenoid valve. Torque connector P18 (4) 24 to 29 lb.in. (2.7-3.3 Nm). |
| (10) | Secure P3 tube assembly (2) to solenoid valve using two bolts (1) , torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (11) | Attach P3 tube assembly with coupling nut (22). Torque coupling nut 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (12) | Install clamp (20) , bolt (19) and nut (18) on bracket (21). Torque nut 27 to 30 lb.in (3.0-3.4 Nm). |
| (13) | Post-SB25095: Install clamp (16) , bolt (15) and nut (14) on the bracket (17) . Torque nut 27 to 30 lb.in (3.0-3.4 Nm). |
| (14) | Assemble by-pass duct (Ref. 72-70-01). |
| (15) | Assemble engine nacelle (Ref. Aircraft Maintenance Manual). |
| (16) | Restore electrical power to appropriate system and reset EEC circuit breaker to ON. |
| (17) | Select maintenance test discrete to OFF. |
| (18) | Refer to Chapter 71-00-00 for checks following installation of anti-ice solenoid valve. |
| (19) | Restore aircraft to normal operating condition (Ref. Aircraft Maintenance Manual). |
| Item No. | Name |
|---|---|
| PWC03-001 | Engine Oil |
| Tool No. | Name |
|---|---|
| PWC60714 | Puller |
| (1) | Remove six bolts (2) or (7), LP bleed pad cover (3) , or shipping cover (8) and cabin air tube retainer (9) , as applicable, and LP bleed pad gasket (4) . Discard gasket (4). |
| (2) | Remove cabin air bleed tube assembly (6) using puller (PWC60714). Remove and discard preformed packings (1) and (5) . |
| (3) | Repeat steps (1 and 2) to remove cabin air bleed tube assembly (6) from opposite side of engine. |
| (4) | Place protective covers on cabin air bleed covers and store in sealable plastic bags. |
| (5) | Remove five bolts (10) and shipping cover from HP bleed air tube (11) . |
| (6) | Remove two bolts (14) securing HP bleed air tube (11) to compressor case. |
| (7) | Remove HP bleed air tube (11). Remove and discard gaskets (12) and (13) . |
| (8) | Repeat steps , and to remove remaining HP bleed air tube. |
| (9) | Place protective covers on bleed air tubes. Store tubes in sealable plastic containers. |
| (1) | Lubricate new preformed packings (1) and (5) and install on cabin air bleed tube assembly (6) . |
| (2) | Install cabin air bleed tube assembly through right-hand LP bleed pad on outer bypass duct; ensure tube is seated in bleed air boss on gas generator case. |
| (3) | Install gasket (4) and cover (3) on LP bleed pad and secure with six bolts (2) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (4) | Lubricate preformed packings (1 and 5) and install on remaining cabin air bleed tube assembly (6). |
| (5) | Install cabin air bleed tube assembly (6) through left-hand LP bleed pad on outer bypass duct; ensure tube is seated in bleed air boss on gas generator. |
| (6) | Install new gasket (4), cabin air tube retainer (9) and shipping cover (8) on LP bleed pad and secure with six bolts (7). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Install new gasket (12) and metal gasket (13) over HP air bleed tube (11) . |
| (8) | Install HP bleed tube (11) through right-hand HP bleed pad on outer bypass duct, and secure with two bolts (14) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (9) | Secure outer flange of HP bleed tube (11) to bleed pad on outer bypass duct with five bolts (10) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (10) | Repeat steps , and to install left-hand HP bleed tube (11). |
| (11) | Place protective covers over right and left-hand HP bleed tubes. |
| (1) | Remove outer bypass duct and inner bypass duct(s) (Ref. 72-70-01) to allow access. |
| (1) | Remove two bolts (1) two washers (2) , gasket (3) and tube assembly (4) . |
| (2) | Remove the three bolts (5) P2.5 bleed valve assembly (6) and gasket (7) . |
| (3) | Loosen bolt and nut (8) . Remove clamp. |
| (1) | Remove bolt (1) , nut (2) and clamp (3) . |
| (2) | Disconnect the coupling nut (13) . |
| (3) | Remove two bolts (4) , washer (5) , tube (6) and gasket (7) . Discard gasket. |
| (4) | Remove bolt (8) and bracket (9) . |
| (5) | Remove two bolts (8), bracket support (10) , gasket (11) and bleed valve (12) . |
| (1) | Remove nut (1) , bolt (2) and clamp (3) . |
| (2) | Disconnect the two coupling nuts (13) . |
| (3) | Remove two bolts (4) , two washers (5) , tube (6) and gasket (7) . Discard gasket. |
| (4) | Remove two bolts (8) and two brackets (9) and (10) . |
| (5) | Remove bolt (8), gasket (11) and bleed valve (12) . |
| (1) | Remove three screws (1) securing bleed valve housing assembly (8) to bleed valve seat (2) . |
| (2) | Remove valve housing (8). |
| (3) | Remove bleed valve piston assembly from valve housing. |
| (4) | Remove sealing ring (7) from piston (4) . |
| (5) | Remove retaining ring (6) and sleeve spacer (5) from piston. |
| (6) | Remove helical spring (3) from valve seat (2). |
| (1) | Install sleeve spacer (5) into compressor bleed valve piston (4) , chamfered edge first. Secure with retaining ring (6) . |
| (2) | Install seal ring (7) into groove on bleed valve piston (4). |
| (3) | Install piston (4) into bleed valve housing (8) . |
| (4) | Install helical spring (3) into groove of piston (4). |
| (5) | Install bleed valve seat (2) . Coat threads of screws (1) with anti-seize compound (PWC06-004) and secure bleed valve seat to bleed valve housing (8). Torque screws 10 to 11.5 lb.in. (1.1-1.3 Nm). |
| (1) | Install the P2.5 bleed valve assembly (6) with gasket (7) three bolts (5) . Torque bolts 35 to 40 lb.in. (4.0-4.5 Nm) dry. |
| (2) | Install tube assembly (4) with gasket (3) , two washers (2) and two bolts (1) . Torque bolts 46 to 50 lb.in. (5.0-5.5 Nm) dry. |
| (3) | Install clamp with bolt and nut (8) . Torque nut 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (1) | Install gasket (11) on bleed valve (12) . Attach bleed valve and support bracket (10) with two bolts (8) . |
| (2) | Install bracket (9) with bolt (8). Torque the three bolts (8) 35 to 40 lb.in. (4.0-4.5 Nm) dry. |
| (3) | Install tube (6) and connect coupling nut (13) . Tighten the coupling nut by hand. |
| (4) | Install gasket (7) on tube (6). Install tube (6) with washer (5) and two bolts (4) . |
| (5) | Install clamp (3) with bolt (2) and nut (1) . |
| (6) | Torque bolts (4) 46 to 50 lb.in. (5.0-5.5 Nm) dry. |
| (7) | Torque coupling nut (13) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (8) | Torque nut (1) 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (9) | Install the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES). |
| (1) | Install gasket (11) , bleed valve (12) and bolt (8) . |
| (2) | Install brackets (9) and (10) with short legs on flange with two bolts (8). |
| (3) | Torque three bolts (8) 35 to 40 lb.in. (4.0-4.5 Nm) dry. |
| (4) | Install tube (6) and connect two coupling nuts (13). Tighten the coupling nuts by hand. |
| (5) | Install gasket (7) on tube (6). Install tube (6) with two washers (5) and two bolts (4) . |
| (6) | Install clamp (3) with bolt (2) and nut (1) . |
| (7) | Torque bolts (4) 46 to 50 lb.in. (5.0-5.5 Nm) dry. |
| (8) | Torque two coupling nuts (13) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (9) | Torque nut (1) 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (10) | Install the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES). |
| (1) | Remove the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES) to allow access. |
| (1) | Remove nuts (1) , bolts (2) and washers (3) . |
| (2) | Remove lockwire and disconnect coupling nut (13). |
| (3) | Remove bolts (5) , washers (6) and support bracket (7) . |
| (4) | Remove tube (4) and gasket (8) . |
| (5) | Remove nut (14) , bolt (15) and clamp (9) . |
| (6) | Remove tube assembly (4). |
| (7) | Remove bolts (10) , bleed valve (11) and gasket (12) . |
| (1) | Remove bolts (1) , washers (2) , tube (8) and gasket (3) . |
| (2) | Remove lockwire and disconnect coupling nut (4). |
| (3) | Remove nut (5) , bolt (6) and clamp (7) . |
| (4) | Remove tube assembly (8) . |
| (5) | Remove bolts (10) , bracket (9) , bleed valve (11) and gasket (12) . |
| (1) | Remove bolts (1) , washers (2) and gasket (3) . |
| (2) | Remove lockwire and disconnect coupling nut (4). |
| (3) | Remove nuts (5) , |
| (4) | bolts (6) and clamps (7) and (8) . |
| (5) | Remove tube assembly (9) . |
| (1) | Remove bottom P2.8 bleed valve tube assembly (Ref. Para. ). |
| (2) | Remove bolts (1) , washers (2) and gasket (3) . |
| (3) | Remove the lockwire and disconnect coupling nut (4). |
| (4) | Remove nuts (5) , bolts (6) , clamps (7) and (8) . |
| (5) | Remove tube assembly (9) . |
| (1) | Remove two bolts (1) , bracket (2) , tube (3) and seal (4) . |
| (2) | Remove nut (5) , bolt (6) , clamps (7) and (8) . |
| (3) | Remove lockwire and disconnect coupling nuts (9). |
| (4) | Remove two bolts (10) , two washers (11) , tube (12) and gasket (13) . |
| (1) | Remove two bolts (1) , tube (2) and seal (3) . |
| (2) | Remove nut (4) , bolt (5) , clamps (6) and (7) . |
| (3) | Remove lockwire and disconnect coupling nut (8). |
| (4) | Remove two bolts (9) , two washers (10) , tube (11) and gasket (12) . |
| (1) | Remove lockwire and disconnect coupling nut (1). |
| (2) | Remove bolts (2) , washers (3) , tube (4) and gasket (5) . |
| (3) | Remove three bolts (6) , brackets (7) and (8) , bleed valve (9) and gasket (10) . |
| (1) | Remove nut (1), bolt (2) and clamp (3). |
| (2) | Remove lockwire and disconnect coupling nut (4). |
| (3) | Remove bolts (5) , washers (6) , tube (7) and gasket (8) . |
| (4) | Remove three bolts (9) , brackets (10) and (11) , bleed valve (12) and gasket (13) . |
| (1) | Remove three screws (1) securing bleed valve housing assembly (8) to bleed valve seat (2) . |
| (2) | Remove valve housing (8). |
| (3) | Remove bleed valve piston (4) from valve housing. |
| (4) | Remove ring (7) from piston (4). |
| (5) | Remove retaining ring (6) and sleeve spacer (5) from piston (4) . |
| (6) | Remove spring (3) from valve seat (2). |
| (1) | Install sleeve spacer (5) into compressor bleed valve piston (4) , chamfered edge first. Secure with retaining ring (6) . |
| (2) | Install seal ring (7) into groove on bleed valve piston (4). |
| (3) | Install piston (4) into bleed valve housing (8). |
| (4) | Install helical spring (3) into groove of piston (4). |
| (5) | Install bleed valve seat (2) . Coat threads of screws (1) with anti-seize compound (PWC06-004) and secure bleed valve seat to bleed valve housing (8). Torque screws 10 to 11.5 lb.in. (1.1-1.3 Nm). |
| (1) | Install gasket (10) , bleed valve (9) and two brackets (7) and (8) with three bolts (6) . Torque bolts 35 to 40 lb.in. (4.0-4.5 Nm) dry. |
| (2) | Install gasket (5) and tube (4) with washer (3) and bolt (2) . |
| (3) | Connect coupling nut (1) and torque 90 to 100 lb.in. (10-11 Nm). Safety the coupling nut with lockwire (PWC05-089). |
| (4) | Torque bolts (3) 46 to 50 lb.in. (5.0-5.5 Nm). |
| (1) | Install gasket (13) , bleed valve (12) and two brackets (10) and (11) , with bolts (9) . Torque bolts 35 to 40 lb.in. (4.0-4.5 Nm) dry. |
| (2) | Install gasket (8) and tube (7) with washers (6) and bolts (5) . |
| (3) | Connect coupling nut (4) and tighten by hand. |
| (4) | Install clamp (3) with bolt (2) and nut (1). Torque nut 27 to 30 lb.in (3.0-3.4 Nm). |
| (5) | Torque bolts (5) 46 to 50 lb.in. (5.0-5.5 Nm). |
| (6) | Torque coupling nut (4) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (1) | Install seal (4) , tube (3) , bracket (2) with two bolts (1) . Torque bolts 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (2) | Install tube (12) and connect coupling nuts (9). Tighten the coupling nut by hand. |
| (3) | Install gasket (13) on tube (12) and attach with two washers (11) and two bolts (10) . |
| (4) | Install clamps (7) and (8) with bolt (5) and nut (6) . Torque nut 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (5) | Torque bolts (10) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (6) | Torque coupling nuts (9) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (1) | Install seal (3) , tube (2) with two bolts (1) . Torque bolts 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (2) | Install tube (11) and connect coupling nut (8). Tighten the coupling nut by hand. |
| (3) | Install gasket (12) on tube (11) and attach with two washers (10) and two bolts (9) . |
| (4) | Install clamps (6) and (7) with bolt (4) and nut (5) . Torque nut 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (5) | Torque coupling nuts (8) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (1) | Install tube (9) and connect coupling nut (4). Tighten the coupling nut by hand. |
| (2) | Install gasket (3) on tube (9) and attach with two washers (2) and bolts (1) . |
| (3) | Attach clamps (7) and (8) with bolts (6) and nuts (5) . Torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (4) | Torque tube coupling nut (4) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (5) | Torque bolts (1) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (1) | Install tube (9) and connect coupling nut (4). Tighten the coupling nut by hand. |
| (2) | Install gasket (3) on tube (9) and attach with two washers (2) and bolts (1) . |
| (3) | Attach clamps (7) and (8) with bolts (6) and nuts (5) . Torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (4) | Torque tube coupling nut (4) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (5) | Torque bolts (1) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (6) | Install bottom P2.8 bleed valve tube assembly (Ref. Para. ). |
| (1) |
Install
gasket (12)
and
bleed valve (11)
with three
bolts (3)
. Torque bolts 35 to 40 lb.in. (4.0-4.5 Nm) dry.
NOTE: Make sure support bracket is correctly positioned behind the bleed valve and not
between the valve and the boss.
|
| (2) | Install clamp (9) , gasket (8) on tube and attach tube-coupling nut (4) fingertight. |
| (3) | Install support bracket (7) with two washers (6) and bolts (5) . Torque bolts 46 to 50 lb.in. (5.0-5.5 Nm). |
| (4) | Torque tube nut (4) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (5) |
Install two
washers (3)
bolts (2)
and
nuts (1)
. Torque bolt 27 to 30 lb.in. (3.0-3.4 Nm) dry.
NOTE: Install washers under bolt heads.
|
| (6) | Install the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES). |
| (1) | Install gasket (12) , bleed valve (11) and bracket (9) with three bolts (10) . Torque bolts 35 to 40 lb.in. (4.0-4.5 Nm) dry. |
| (2) | Install three clamps (9) on tube (8) and connect tube-coupling nut (4) fingertight. |
| (3) | Attach clamps (7) with bolts (6) and nuts (5) . |
| (4) | Install gasket (3) on tube (8) and attach with two washers (2) and bolts (1) . Torque bolt 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (5) | Torque tube coupling nut (4) 90 to 100 lb.in. (10-11 Nm) and safety with lockwire (PWC05-089). |
| (6) | Install the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES). |
| (1) | Visual checks:
|
| (6) | Dimensional checks:
|
| (1) | Visual checks:
|
| (5) | Dimensional checks:
|
| (1) | Visual checks:
|
| (3) | Dimensional checks:
|
| (1) | Visual checks:
|
| (5) | Dimensional checks:
|
| (1) | Visually inspect all four BOV’s in situ. Check the general condition and cleanliness of the valves. |
| (2) | Make sure that all BOV’s are in fully open position. |
| (3) | Do the bleed valve operational check (Ref. 71-00-00, POWER PLANT - ADJUSTMENT/TEST). |
| (1) | Make sure Power Switch of flowmeter (PWC60790) is OFF and safety pin is installed. |
| (2) | Make sure air pressure valve is CLOSED. |
| (3) | Make sure flow meter adjustment is turned in, fully CW. |
| (4) | Make sure 110 VAC is not connected. |
| (1) | Disconnect engine P3 supply tube from the handling, upper, BOV solenoid valve. |
| (2) | Disconnect engine wiring harness connector J30, Channel B, from bypass duct. |
| (3) | Install wiring harness connector from flowmeter on J30 receptacle on bypass duct. |
| (4) | Connect air supply tube from flowmeter to upper BOV solenoid using slave gasket, bolts and washers. Torque bolts 36 to 40 lb. in. (4.1-4.5 Nm). |
| (5) | Visually check that all three bleed valves are OPEN. |
| (6) | Connect shop air to flowmeter. |
| (7) | Set pressure to 100 psi. |
| (8) | Open air pressure valve. |
| (9) | Turn flowmeter adjustment out, CCW, two turns. |
| (10) | Visually check that all BOVs remain OPEN. If the BOVs start to close, the solenoid is stuck open and must be replaced. |
| (11) | Connect 110 VAC to flowmeter. |
| (12) | Turn power switch ON to energize BOV solenoid. |
| (13) | Visually check that all 3 bleed valves CLOSE. |
| (14) | Record BOV leakage shown on flow meter.
NOTE: Read the value from the bottom of the ball on the flow meter.
|
| (15) | The maximum allowable leakage is 26.5 SCFH. |
| (16) | If leakage exceeds limit (Ref. Step ), put leak check fluid (PWC05-007) on all connecting flanges to determine source of leak. |
| (17) | If leaks are present at flanges replace gasket, re-torque bolts and repeat test. |
| (18) | If leakage still exceeds limit (Ref. Step ), check individual components (Ref. Para. and ). |
| (19) | Turn power switch OFF and visually check that all three valves OPEN under spring pressure. |
| (20) | If any valve does not open, tap it lightly with a rubber hammer. |
| (21) | If the bleed valve still does not open, replace the valve and repeat the test. |
| (22) | If it is required to work around bleed valves while test equipment is still attached
to engine, the following precautions must be taken:
|
| (25) | Reduce control pressure to zero, close the air pressure valve and turn flowmeter adjustment fully IN, CW. |
| (1) | Disconnect P3 supply line to the start, lower, BOV solenoid valve. |
| (2) | Remove outer wiring harness connector J30. |
| (3) | Connect P3 solenoid line to AIR OUT of flowmeter with gasket, washers and bolts. Torque bolts 36 to 40 lb. in. |
| (4) | Connect test cable to connector J30. |
| (5) | Visually check that starting BOV is OPEN. |
| (6) | Adjust flowmeter to 100 psi, open air pressure valve and turn flowmeter adjustment out, CCW, two turns. |
| (7) | Visually check that start BOV is still OPEN. If valve starts to close, the solenoid is stuck open and must be replaced. |
| (8) | Connect 110 VAC. |
| (9) | Turn flowmeter power switch ON to energize solenoid. |
| (10) | Visually check that start BOV CLOSES. |
| (11) | Record BOV system leakage.
NOTE: Read the value from the bottom of the ball on the flowmeter.
|
| (12) | Max leakage is 10.9 SCFH. |
| (13) | If leakage exceeds limits (Ref. Step ) apply leak check fluid (PWC05-007) to all connecting flanges. If leaks are present at flanges replace gasket, re-torque bolts and repeat Steps thru ). |
| (14) | If leakage is still above limits (Ref. Step ) check individual components (Ref. Para and following). |
| (15) | Turn flowmeter power switch OFF. |
| (16) | Visually check that start BOV opens under spring action. |
| (17) | If valve does not open, tap housing lightly with rubber faced hammer. If it still does not open, the valve may be seized and must be replacing. |
| (18) | If it is required to work around bleed valves while test equipment is still attached
to engine, the following precautions must be taken:
|
| (21) | Reduce control pressure to zero, close the air pressure valve and turn flowmeter adjustment fully IN, CW. |
| (1) | Disconnect P3 air out from the solenoid. |
| (2) | Install blanking cover with gasket. Torque bolts 36 to 40 lb. in. |
| (3) | Adjust control pressure to 100 psi, open air pressure valve and turn flowmeter out (CCW) two turns. |
| (4) | Turn power switch ON and check for leaks, max. 3 SCFH. |
| (5) | Turn power switch OFF and remove blanking cover. |
| (6) | Check for leakage, max. 3 SCFH. |
| (7) | Reduce control pressure to zero, close the air pressure valve and turn flowmeter in (CW) two turns. |
| (8) | Remove air line from the upper solenoid. |
| (9) | Remove 110 VAC from flowmeter. |
| (10) | Remove test cable from connector J30. |
| (11) | Replace solenoid if air leak limit (Ref. Step ) is exceeded. |
| (1) | Disconnect the air supply to the valve to be tested. |
| (2) | Connect flowmeter AIR OUT to the BOV with gasket, washers and bolts. Torque bolts 36 to 40 lb. in. |
| (3) | Adjust flowmeter to 100 psi, open air pressure valve and turn flowmeter adjustment out, (CCW), two turns. |
| (4) | Visually check to see that the bleed valve CLOSES. |
| (5) | Check leakage is 7.9 SCFH. |
| (6) | Replace valve if limit is not met. |
| (7) | Reduce control pressure air pressure to zero, and check that valve CLOSES. |
| (8) | Disconnect flowmeter from BOV. |
| (9) | Repeat for remaining BOVs. |
| Item No. | Name |
|---|---|
| PWC05-089 | Lockwire |
| (1) | Remove the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES) to allow access. |
| (1) | Remove nut (1) bolt (2) and clamp (3) on tube (4) from bracket (5). |
| (2) | Remove bolt (2) from bracket (6) and clamp (3) on tube (4). |
| (1) | Remove nuts (1) , bolts (2) and clamps (3) . |
| (2) | Remove bolt (6) and clamp (7) . |
| (3) | Remove two bolts (8) , two washers (9) , tube (4) and gasket (10) . Discard the gasket. |
| (4) | Remove the coupling nut (5) and tube (4). |
| (1) | Disconnect P13 connector (12), P14 connector (13), P37 connector (14) and P38 connector (15). |
| (2) | Remove two nuts (1) and bolts (2) from bracket (3) . Remove solenoid valve (4) . |
| (3) | Remove one washer (5) two bolts (6) adapter (7) and gasket (8) . |
| (4) | Remove two nuts (9) bolts (10) and solenoid valve (11) . |
| (1) | Install solenoid valve (1) with two bolts (2) and nuts (3) . Torque nuts fingertight. |
| (2) | Install adapter (4) and gasket (5) with two bolts (6) and one washer (7) . Torque bolts fingertight. |
| (3) | Attach solenoid valve (8) to bracket (9) with two bolts (10) and nuts (11) . Torque nuts 27 to 30 lb. in. dry. |
| (4) | Engage master keyway and install P13 connector (12) to the fan side and P14 connector
(13) to the exhaust side on the upper compressor bleed valve solenoid. Tightly hold
the connector coupling nut with soft-jawed pliers (PWC90012) and apply hand pressure to tighten the nut until the pliers slip.
NOTE: Measurement of the actual torque is not required.
|
| (5) | Engage master keyway and install P37 connector (14) to the fan side and P38 connector
(15) to the exhaust side on the lower compressor bleed valve solenoid. Tightly hold
the connector coupling nut with soft-jawed pliers (PWC90012) and apply hand pressure to tighten the nut until the pliers slip.
NOTE: Measurement of the actual torque is not required.
|
| (1) |
Removal of Upper Solenoid Valve:
|
| (7) | Removal of Lower Solenoid Valve:
|
| (1) | Installation of Upper Solenoid Valve:
|
| (7) | Installation of Lower Solenoid Valve:
|
| (1) | Install tube (4) on bracket (6) with clamp (3) and bolt (2). Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Install clamp (3) on tube (4) and attach to bracket (5) with bolt (2) and nut (1) . Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Install tube (4) with gasket (10) , two washers (9) and two bolts (8) . Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Install the tube coupling nut (5) and torque the nut 90 to 100 lb.in. (10-11 Nm). |
| (3) | Install clamp (7) and bolt (6) . Torque nut 27 to 30 lb.in. (3.0-3.4 Nm) dry. |
| (4) | Install clamps (3) with nuts (1) and bolts (2) on tube (4). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Install tube (1) to P3 solenoid adapter (2) , attach clamp (3) with bolt (4) and nut (5) . Torque fingertight. |
| (2) | Install the outer bypass duct and inner bypass duct(s) (Ref. 72-70-01, BYPASS DUCTS - MAINTENANCE PRACTICES). |
| Item No. | Name |
|---|---|
| PWC05-089 | Lockwire |
| Tool No. | Name |
|---|---|
| PW58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Disconnect the P39 harness connector from P3 transducer (2) . Check connector for moisture. If present dry with suitable heat gun. |
| (2) | Disconnect the coupling nut of the P3 air tube assembly (3) from P3 transducer (2). |
| (3) | Remove two bolts (9) and P3 transducer (2). |
| (4) | Disconnect the coupling nut and remove P3 air pressure tube (3). |
| (5) | Remove cap assembly (4) . |
| (6) | Remove two bolts (6) and (8) . |
| (7) | Disconnect the coupling nut and remove P3 tube assembly (1) . |
| (8) | Remove two loop clamps (5) and (7) . |
| (1) | Install P3 air pressure transducer (2) on bypass duct. Attach with two bolts (9) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (2) | Install P3 tube (1) on the outer bypass duct. Tighten coupling nut hand tight. |
| (3) | Install P3 air tube assembly (3) between transducer (2) and tube assembly (1). Tighten coupling nuts hand tight. |
| (4) | Install loop clamps (5) and (7) on tube assembly (1). Attach with bolts (6) and (8) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (5) | Torque the coupling nuts of tube assemblies (1) and (3) 270 to 300 lb.in. (30.5-34.0 Nm) and lockwire with (PWC05-089). |
| (6) | Install cap assembly (4) on P3 tube (1). Torque cap 270 to 300 lb.in. (30.5-34.0 Nm) and lockwire with (PWC05-089). |
| (7) |
Install harness connector P39 on transducer (2). Tighten the connector using one of
the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| Tool No. | Name |
|---|---|
| PWC43312 | Rigging Pin |
| PW58104 | Wrench Assembly Connector |
| PWC60802 | Rigging Tool |
| PWC90025 | Crimper |
| PWC90026 | Test Block |
| PWC90012 | Soft Jawed pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Remove the access cowling and apron (Ref. Aircraft Maintenance Manual). |
| (3) | Remove the right and left forward, upper, outer, bypass ducts (Ref. 72-70-01, BYPASS DUCTS, MAINTENANCE PRACTICES). |
| (4) | Remove the upper left and right, inner, bypass duct segments (Ref. 72-70-01, BYPASS DUCTS, MAINTENANCE PRACTICES). |
| (5) | Remove lockwire from nuts (3) , (19) , (7) and (14) and internally threaded rods (22) and (6) . |
| (6) | While holding rod (6), loosen nuts (3 and 19). |
| (7) | While holding rod (22), loosen nuts ( 7 and 14). |
| (8) | Move actuator shaft (5) to the closed position. |
| (9) | Remove cotter pin (9) , nut (8) and bolt (12) . |
| (10) | Remove cotter pin (2) , nut (1) . |
| (11) | Remove bolt (34) securing the actuator rod to the master lever. |
| (12) | Remove two bolts (29) attaching fuel tube assembly (28) to actuator manifold. Loosen or remove bolts along the length of tube assembly (28) as necessary to ease retraction. |
| (13) | Remove threaded rods (6 and 22). Remove master lever (18) . |
| (14) | Disconnect the P24 and P25 connectors (25 and 26). Remove four clamps/brackets securing actuator harness. Make note of the orientation and locations of the clamps and brackets. |
| (15) | Remove actuator harness connector attaching nuts (35, 36). Remove connector (30) and (31). |
| (16) | Remove four bolts (24) securing actuator to mounting bracket (11). Remove actuator (23) . |
| (17) | Remove and discard preformed packings (32, 33). |
| (18) | Install protective covers on all tube and actuator openings. |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Install nut (3) on rod-end (4) . |
| (3) | Install nut (7) on rod-end (10) . |
| (4) | Move IGV (16) and first-stage vane rings (15) to the closed position. |
| (5) | Lubricate and install two new preformed packings (32) and one new preformed packing (33) on actuator (23) using engine oil (PWC03-001). |
| (6) | Position actuator (23) on bracket (11) engaging tube assembly (28). Attach actuator with four bolts (24) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (7) | Attach tube assembly (28) to actuator (23) with bolts (29). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Install nut (19) on rod-end (20). |
| (9) | Install nut (14) on rod-end (17). |
| (10) | Position master lever assembly (18) in gas generator case (21) . |
| (11) | Connect yoke (13) to bracket (11) with bolt (12) and nut (8) . Torque nut 90 to 100 lb. in. (10.1-11.3 Nm). Install cotter pin (9) . |
| (12) | Move actuator rod (5) toward the open position until holes of rod (5) and master lever (18) are aligned, and install bolt (34) and nut (1) . Torque nut 90 to 100 lb. in. (10.1-11.3 Nm) and install cotter pin (2) . |
| (13) | Install threaded rod (22) on rod ends (4) and (20) and threaded rod (6) on rod ends (10) and (17) . |
| (14) | Adjust threaded rods (22 and 6) simultaneously until the results are as follows:
|
| (17) | Replace or torque any clamps or bolts affected during removal of tube actuator. |
| (18) | Position actuator harness in the same location as noted at disassembly. Install actuator wiring harness (1) with four clamps (2) and bracket (3) (Ref. Fig. ). |
| (19) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (20) | Attach connectors (30 and 31) to bracket (27) with nuts (35 and 36). Torque nut 45 to 50 lb. in. (5.08-5.65 Nm.) and install lockwire (PWC05-089). |
| (21) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (22) | Engage master keyway and install P24 connector (26) and P25 connector (25) on stator vane actuator. |
| (23) |
Tighten the connectors (25 and 26) using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (26) | Measure the clearance between actuator wiring harness and secondary air tube. The
clearance should be 0.125 in. (3.18 mm) minimum.
NOTE: Actuator wiring harness clamps can be adjusted to get clearance.
|
| (27) | Rig actuator (Ref Subpara. following). |
| (1) | Move actuator rings (15 and 16) toward the open position until rigging pins (PWC43312) can be inserted through VIGV ring (16) and first-stage compressor vane (15) into the slot in the left side HP compressor case. |
| (2) | Adjust threaded rods (22 and 6) simultaneously until rigging tool (PWC60802) can be installed through rod (5) and housing (23). |
| (3) | Adjust threaded rods (6 and 22) until rigging pin (PWC43312) and tool (PWC60802) can be easily inserted and removed simultaneously. |
| (4) | Check that rods are in safety by trying to pass a 0.050 to 0.055 inch (1.2-1.4 mm) diameter wire through each witness hole of each threaded rod. Wire must not pass through. |
| (5) | Turn rod-ends until the bearing housings are parallel in the attaching brackets. |
| (6) | Hold threaded rod and tighten locknuts (3 and 19) 90 to 100 lb.in. (10-11.3 Nm). |
| (7) | Install safety cable on locknuts (3 and 19) and turnbuckle (22) with crimper (PWC90025) and test block (PWC90026) (Ref. Chapter 70-00-00, MAINTENANCE PRACTICES).
NOTE: If possible, set safety cable short ferrule at turnbuckle hole (22).
|
| (8) | Hold threaded rod and tighten locknuts (7) and (14) 90 to 100 lb.in. (10-11.3 Nm). |
| (9) | Install safety cable on locknuts (7 and 14) and turnbuckle (6) with crimper (PWC90025) and test block (PWC90026) (Ref. Chapter 70-00-00, MAINTENANCE PRACTICES).
NOTE: If possible, set safety cable short ferrule at turnbuckle hole (6).
|
| (10) | Make sure that safety cable ferrules does not touch actuator bracket by moving actuator ring drive system to fully close and fully open position. |
| (11) | Remove rigging tool (PWC60802) and pins (PWC43312). |
| (12) | Restore electrical power and reset EEC circuit breaker to ON. |
| (13) | Select maintenance test discrete to OFF. |
| (14) | Install the upper left and right, inner, bypass duct segments (Ref. 72-70-01, BYPASS DUCTS, MAINTENANCE PRACTICES). |
| (15) | Install the right and left forward, upper, outer, bypass ducts (Ref. 72-70-01, BYPASS DUCTS, MAINTENANCE PRACTICES). |
| (16) | Install the access cowling and apron (Ref. Aircraft Maintenance Manual). |
| (17) | Refer to Chapter 71-00-00, POWER PLANT - ADJUSTMENT/TEST for checks following installation of IGV actuator. |
| • | Assist in engine fault isolation by recording exceedances, events, fault codes by displaying real time engine parameters and status words. |
| • | Assist in Engine Condition Trend Monitoring (ECTM) with snap shot recording. |
| • | Assist in flight and total time counting by recording engine/aircraft flight cycle and total time. |
| • | Data Base Unit (DBU): Used to download diagnostic data to a 3.5 inch floppy disk. |
| • | Display Control Panel (DCP): Provides keys for controlling the Multi Function Display. |
| • | Multi-Function Display (MFD): Used for displaying the EDS data when in maintenance mode. |
| • | Aircraft Maintenance Switch (in cockpit): The switch is located on the right side of the pedestal (co-pilot side). The switch when actuated to ON position will re-configure the MFD to display maintenance mode menus and activate the EDS system display. |
| • | Pilot Manual Request Buttons: The two buttons (one each for left hand and right hand engines) are also located on the right side of the pedestal (co-pilot side). The request buttons will allow the pilot or technician to record engine parameters into the EDS memory in case of abnormal engine operation (fluctuation, abnormal loss of power, sudden ITT split, etc.). This information can be later extracted by the technician for assistance in fault isolation. |
| Item No. | Name |
|---|---|
| PWC06-009 | Compound, Antiseize |
| Tool No. | Name |
|---|---|
| PW58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| Glenair TG70 Wrench Assembly Connector |
| (1) | Channel A and Channel B Removal (Ref. Fig. ):
|
| (1) | Channel A and Channel B Installation (Ref. Fig. ):
CAUTION: BEFORE APPLYING THE TORQUE TO THE BOLTS, MAKE SURE THE N1 SPEED SENSOR CABLE ROUTING
THROUGH THE EXHAUST CASE AND GUIDE TUBE IS CORRECT.
|
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Drain oil from accessory gearbox (2) (Ref. 72-00-00, SERVICING). |
| (3) | Disconnect outer wiring harness connector P9 (7). |
| (4) | Remove two bolts (6) and washers (5) . |
| (5) | Remove speed sensor (4) and discard preformed packing (3) . |
| (1) | Install new preformed packing (3) on speed sensor (4). |
| (2) | Insert speed sensor (4) into boss in accessory gearbox (2) with two bolts (6) and washers (5) . Tighten bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (3) | Apply electrical contact enhancer to connectors (Ref. Chapter 70-00-00, CLEANING). |
| (4) |
Connect outer wiring harness connector P9 (7) to N2 speed sensor (4). Tighten the
connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS.
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (7) | Install accessory gearbox drain plug (Ref. Chapter 72-00-00, SERVICING), and service as required. |
| (8) | Restore electrical power to appropriate system and reset EEC circuit breaker ON. |
| (9) | Select maintenance test discrete OFF. |
| (10) | Pull EEC circuit breaker to OFF. |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Drain oil from accessory gearbox (2) (Ref. 72-00-00, SERVICING). |
| (3) | Disconnect outer wiring harness connector P10 (8). |
| (4) | Remove two bolts (9) washer (10) loop clamp (13) . |
| (5) | Remove speed sensor (11) and discard preformed packing (12) . |
| (1) | Install new preformed packing (12) on speed sensor (11) . |
| (2) | Insert speed sensor (11) into boss in accessory gearbox (2) and secure with two bolts (9) washer (10) and loop clamp (13) . Tighten and torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (3) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (4) |
Connect external wiring harness connector P10 (8) to N2 speed sensor (11). Tighten
the connector using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (7) | Install accessory gearbox drain plug(Ref. 72-00-00, SERVICING), and service as required. |
| (8) | Restore electrical power to appropriate system and reset EEC circuit breaker ON. |
| (9) | Select maintenance test discrete OFF. |
| (10) | Pull EEC circuit breaker to OFF. |
| Name | Remarks |
|---|---|
| Barfield Test Set | Model TT-1000A |
| (1) | Remove four self-locking nuts (12) and terminal box cover (13). |
| (2) | Remove self-locking nuts alumel (21), chromel (20) and remove T4.5 wire connectors (7, 14 and 25) from terminal block (23). |
| (3) | Remove lockwire and unscrew "T4.5 OUT" harness connector (15) from terminal box (19) . |
| (4) | Remove lockwire and unscrew "T4.5 IN" harness connectors (1) and (16) from terminal box (19). |
| (5) | Remove 12 self-locking nuts (22) from bus-bars (24) and remove wire connections. |
| (6) | Remove lockwire and unscrew "N1 OUT" harness connectors (17 and 18) from terminal box (19). |
| (7) | Remove self-locking nut (8), bolt (11) and bracket (9) from terminal box (19). |
| (8) | Withdraw "N1 IN" cables (2 and 3) from terminal box (19). |
| (9) | Remove three self-locking nuts (6) , three bolts (10) and remove terminal box from support (5). |
| (10) | Remove three bolts (4) and terminal box support (5) from Flange E. |
| (1) | Secure terminal box support (5) on Flange E with three bolts (4). Torque 85 to 95 lb.in. (9.5-11.0 Nm). |
| (2) | Install terminal box (19) on terminal support (5) with three self-locking nuts (6) and bolts (10) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (3) | Insert "N1 OUT CH. B" harness (18) into terminal box (19). Torque harness coupling nut 45 to 55 lb.in. (5.0-5.5 Nm). |
| (4) | Insert "N1 OUT CH. A" harness (17) into terminal box (19). Torque harness coupling nut 45 to 55 lb.in. (5.0-5.5 Nm). |
| (5) | Lockwire (PWC05-089) coupling nuts on harness (17 and 18). |
| (6) | Install N1 wire connections on bus bar (24). Refer to View A for color coding. |
| (7) | Insert N1 cables (2 and 3) into terminal box (19) and secure with bracket (9) and self-locking nut (8). Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (8) | Install wire connections on bus-bar (24). Refer to View A for color coding. Torque post nuts (22) 3.5 to 4 lb.in. (0.3 - 0.4 Nm). |
| (9) | Install "T4.5 IN" cables (1, 16) to terminal box (19). Torque coupling nuts 15 to 25 lb.in. (1.6-2.8 Nm) and lockwire (PWC05-089). |
| (10) | Install "T4.5 OUT" cable (15) in terminal box (19). Torque 15 to 25 lb.in. (1.6-2.8 Nm). |
| (11) | Install T4.5 wire connections (7, 14 and 25) on terminal block (23) with self-locking nuts; chromel (20) and alumel (21). Refer to View A for correct installation. |
| (12) | Install large alumel nut (21) and torque 24 to 40 lb. in. (2.8-4.6 Nm). |
| (13) | Install small chromel nut (20) and torque 15 to 20 lb.in. (1.6-2.8 Nm). |
| (14) | Lockwire (PWC05-089) coupling nuts (15 and 16). |
| (15) | Secure terminal box cover (13) with four self-locking nuts (12). Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (1) | Remove four self-locking nuts (1) and terminal box cover (2) . |
| (2) | Remove the nuts (6) and disconnect N1 speed probes wire connection from the terminal strip (5) . |
| (3) | Remove nuts (3) and spacers (4). |
| (4) | Remove and discard the terminal strip (5). |
| (1) | Install new terminal strip(s) (5) |
| (2) | Install spacers (4). |
| (3) | Install self-locking nuts (3). |
| (4) | Torque nuts (3) to 32 to 36 lb.in. (3.6-4.0 Nm). |
| (5) | Install N1 speed probes wire connection to the terminal strip (5), refer to figure for color coding. |
| (6) | Install the nuts (6). Torque nuts 3.5 to 4 lb.in. (0.3-0.4 Nm). |
| (7) | Attach terminal box cover (2) with four self-locking nuts (1). Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (1) | Select maintenance test discrete ON before wiring harness removal (Ref. Aircraft Maintenance Manual). |
| (2) | Disconnect the electrical power to appropriate system and pull EEC circuit breaker to the OFF position. |
| (3) | Disconnect T4.5 wiring harness from N1/T4.5 terminal box (Ref. Para. ). |
| (4) | Remove four nuts (4) , bolts (3) and loop clamp (5) . |
| (5) | Remove bolts (6) on bracket (10) and retain bracket (13). |
| (6) | Remove two bolts (6) and bracket (14). |
| (7) | Remove 16 bolts (8) securing T4.5 probes in LP turbine case. |
| (8) | Carefully remove two wiring harnesses (1) from engine. Discard eight ring-seals (12) and gasket (11) . |
| (1) | Apply a light coat of anti-seize compound (PWC06-009) to eight new ring-seals (12) and install on T4.5 probes (9). |
| (2) | Install eight new gasket (11) on T4.5 probes and carefully insert probes into their respective bosses on LP turbine case. |
| (3) | Apply a light coat of anti-seize compound (PWC06-009) to 16 bolts (8) and secure T4.5 probes to LP turbine case. Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (4) | Secure bracket (10), part of lower wiring harness together with bracket (15) at the 8 o'clock position using two bolts (6). Torque bolts 85 to 95 lb.in. (9.5-11 Nm). |
| (5) | Secure other bracket (10), part of upper wiring harness with bracket (13) at the 2 o'clock position, and using bolts (6). Torque bolts 85 to 95 lb.in. (9.5-11 Nm). |
| (6) | Install two bolts (6) and bracket (14). Torque bolts 85 to 95 lb.in. (9.5-11 Nm) |
| (7) | Install four loop clamp (5) bolts (3) and self-locking nuts (4) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Connect T4.5 wiring harnesses (1) to N1/T4.5 terminal box (2) (Ref. Para. ). |
| (9) | Restore electrical power to appropriate system and reset EEC circuit breaker ON. |
| (10) | Select maintenance test discrete OFF after wiring harness installation and before engine operations (Ref. Aircraft Maintenance Manual). |
| (11) | Refer to Chapter 71-00-00 for checks following installation of T4.5 thermocouple wiring harness. |
| (1) | Remove chromel and alumel nuts (20 and 21). |
| (2) | Remove T4.5 IN and OUT wires from terminal block (23). |
| (3) | Remove bolts, nuts, and terminal block (23) from terminal box (19). |
| (1) | Install terminal block (23) inside terminal box (19) with bolts, bolt heads outside box, and nuts. |
| (2) | Torque nuts 32 to 36 lb. in. |
| (3) | Fit T4.5 IN and OUT wires on terminal block (23). Refer to View A for correct location. |
| (4) | Install large alumel nut (21) and torque 24 to 40 lb. in. (2.8-4.6 Nm). |
| (5) | Install small chromel nut (20) and torque 15 to 20 lb.in. (1.6-2.8 Nm). |
| (6) | Check function of T4.5 system (Ref. Para. ). |
| (1) | Information transferred to ADJUSTMENT/TEST. |
| (2) | Inspect wiring as follows:
|
| (6) | Inspect metal tubing as follows:
|
| (10) | Check connector threads for damage. Chase threads using a 0.500-20UNJF 3A die. |
| (11) | Inspect thermocouple probes as follows (Ref. Fig. ):
|
| (1) | Do the continuity resistance check as follows:
NOTE: Examine multi-tester or ohmmeter calibration before you do the resistance check.
|
| (6) | Do the insulation resistance check as follows:
|
| (1) | Do the continuity resistance check of the external wiring harness as follows:
NOTE: Examine multi-tester or ohmmeter calibration before you do the resistance check.
|
| (8) | Do the insulation resistance check as follows:
|
| (1) | Do the continuity resistance check of the rear core harness assembly as follows:
|
| (7) | Do the insulation resistance check of the rear core harness assembly as follows:
|
| (1) | Do the continuity resistance check of upper and lower T4.5 thermocouple harnesses
as follows:
NOTE: Examine multi-tester or ohmmeter calibration before you do the resistance check.
|
| (10) | Examine the insulation resistance of the upper and lower T4.5 thermocouple harness
and terminal block:
|
| (1) | Disconnect the terminals (7, 14 and 25) (Ref. Para. ). |
| (2) | Remove the upper and/or lower T4.5 thermocouple harness from the engine (Ref. Para. ). |
| (3) | Connect the tester leads to upper T4.5 thermocouple harness terminals (7) (Ref. Fig. ). |
| (4) | Heat each thermocouple tip one after the other and make sure that there is a voltage reading indication is in the same direction for each thermocouple. |
| (5) | Do step thru step again to test the lower T4.5 thermocouple harness terminals (14) (Ref. Fig. ). |
| (6) | If the insulation resistance check fails and the engine was not operating just before this check, bake the thermocouple assembly at 93°C (200°F) to dry out possible moisture and do the check 4 again (Ref. Para. ). |
| (7) | Replace the thermocouple assembly if any of the four thermocouples does not react properly to heat, or insulation resistance check is not within the specified limits. |
| (8) | Install the T4.5 thermocouple harnesses again on the engine (Ref. Para. ). |
| (9) | Connect the thermocouple terminals again (Ref. Para. ). |
| Tool No. | Name |
|---|---|
| PWC58104 | Wrench Assembly Connector |
| PWC90012 | Soft Jawed Pliers |
| Name |
|---|
| Glenair TG69 Soft Jawed Pliers |
| (1) | Select maintenance test discrete ON (Ref. Aircraft Maintenance Manual). |
| (2) | Remove electrical connectors P22 (10) and P23 (4) from sensors (9) and (8). |
| (3) | Remove lockwire and disconnect coupling nut (5) on P1 tube (6) from sensor (8). |
| (4) | Remove two bolts (12), washers (11), nuts (7) and P1/T1 sensors (8, 9) from shipping brackets (13), or remove P1/T1 sensors from engine inlet cowl (Ref. AMM) as applicable. |
| (5) | If sensor (9) is being replaced, remove cap (3) . |
| (6) | If applicable, remove four bolts (14), nuts (1), washers (2) and shipping brackets (13). |
| (7) | Place protective covers on electrical connectors and tube ends. |
| (1) | If applicable, install two shipping brackets (13) with two bolts (14), washers (2) and nuts (1). Torque nuts 27 to 30 lb.in. (3.0-3.3 Nm). |
| (2) | Install cap (3) on sensor (9) . Torque cap 70 to 80 lb.in. (7.9-9.0 Nm) and secure with lockwire (PWC05-089). |
| (3) | Install P1/T1 sensors (8, 9) with two washers (11), bolts (12) and nuts (7), on shipping brackets (13) or engine inlet cowl (Ref. AMM) as applicable. |
| (4) | Torque nuts (7) 36 to 40 lb.in. (4.0-4.6 Nm) at each location. |
| (5) | Apply anti-seize compound (PWC06-009) to coupling nut (5). |
| (6) | Torque coupling nut (5) 50 to 60 lb.in. (5.6- 6.7 Nm) and secure with lockwire (PWC05-089). |
| (7) | Apply electrical contact enhancer to connectors (Ref. 70-00-00, CLEANING). |
| (8) |
Attach connectors (10, 4) to P1/T1 sensors (9, 8). Tighten each connector by hand
until witness band on the mating receptacle is covered. Tighten the connector using
one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (11) | Select maintenance test discrete OFF (Ref. Aircraft Maintenance Manual). |
| (1) | Remove lockwire and disconnect coupling nut (16) from sensor (19) . |
| (2) | Remove lockwire and disconnect coupling nut (10) from tube (11) . |
| (3) | If applicable, remove bolt (3), loop clamp (4) and nut (5) from shipping bracket (2). |
| (4) | If applicable, remove bolt (12), loop clamp (13) and nut (7) from shipping bracket (9) and remove air tube (6). |
| (5) | If applicable, remove shipping brackets as follows:
|
| (1) | If applicable, install shipping brackets as follows:
|
| (4) | Apply anti-seize compound (PWC06-009) to coupling nuts (10, 16). |
| (5) | Install air tube (6) to sensor (19) and tube (11) . Tighten coupling nuts (10, 16) fingertight. |
| (6) | Install loop clamp (4) on tube (6) and secure to shipping bracket (2) if applicable, with bolt (3) and nut (5), or inlet cowl (Ref. AMM) as applicable. Torque nuts (5) 27 to 30 lb.in. (3.0-3.3 Nm). |
| (7) | Install loop clamp (13) on tube (6) and secure to shipping bracket (9) if applicable, with bolt (12) and nut (7), or inlet cowl (Ref. AMM) as applicable. Torque nuts (5) 27 to 30 lb.in. (3.0-3.3 Nm). |
| (8) | Torque tube coupling nuts (10, 16) 50 to 60 lb.in. (5.6-6.7 Nm) and secure with lockwire (PWC05-089). |
| (1) | Remove lockwire and disconnect coupling nut (2) from tube (11) . |
| (2) | Remove lockwire and disconnect coupling nut (7) from EEC fitting (15). |
| (3) | Remove bolts (9) , (10) nut (14) , loop clamp (13) and bracket (8) from tube (11). |
| (4) | Remove bolt (3) nut (16) , loop clamp (4) . |
| (5) | Remove bolt (6) and bracket (5) from EEC. |
| (6) | Remove lockwire and remove cap (12) . |
| (1) | Install cap (12) on tube (11) . Torque cap 90 to 100 lb.in. (10.1-11.2 Nm) and secure with lockwire (PWC05-089). |
| (2) | Apply anti-seize compound (PWC06-009) to coupling nut (2). |
| (3) | Install air tube (11) to coupling nut (2) of P1 air tube (1) and EEC fitting (15). Tighten coupling nuts (2, 7) fingertight. |
| (4) | Torque coupling nut (2) 50 to 60 lb.in. (5.6-6.7 Nm) and secure with lockwire (PWC05-089). |
| (5) | Torque coupling nut (7) 50 to 60 lb.in. (5.6-6.7 Nm) and secure with lockwire (PWC05-089). |
| (6) | Install bolt (10) and bracket (8) . Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (7) | Install bolt (9) , loop clamp (13) and nut (14) . Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (8) | Install bolt (6) and bracket (5) . Torque bolt 36 to 40 lb.in. (4.1-4.5 Nm). |
| (9) | Install bolt (3) , loop clamp (4) and nut (16) . Torque 27 to 30 lb.in. (3.0-3.3 Nm). |
| Tool No. | Name | Application |
|---|---|---|
| PWC58104 | Wrench Assembly Connector |
|
| PWC61969 | Cable, GBS Download | (See NOTE 1 and NOTE 2) |
| PWC90012 | Soft Jawed Pliers |
|
| PWC90191 | Adapter, USB to RS 232 | (See NOTE 1 and NOTE 2) |
|
NOTE: 1. Ref. INTRODUCTION for more details.
|
||
|
NOTE: 2. The cable equipment that is included in the DPHM kit may be purchased separately
through all tooling suppliers.
|
||
| Name | Remarks |
|---|---|
| 3072681, DPHM Kit | (See NOTE) |
| Glenair TG69 Soft Jawed Pliers |
|
| Glenair TG70 Wrench Assembly Connector |
| (1) | Power ON the EICAS and EDS system (Ref. AMM). |
| (2) | Select maintenance switch to ON, buttons ED, PFD to OUT positions and turn the Data Control Panel (DCP) Mode key clockwise to select to Maintenance Mode on the MFD. (Refer to the Aircraft Maintenance Manual for switches and push button locations and functions). |
| (3) | The maintenance menu will be displayed on the MFD. Use the keys in the DCP to go to
the desired menu as follows:
NOTE: The lettered keys are used and the function of each key is defined at the bottom
of each screen.
|
| (4) | From the maintenance menu move the cursor using the DCP keys and select "Propulsion
System Diagnostic" to access the selection menu for engine diagnostic system.
NOTE: By selecting "PROPULSION SYSTEM DIAGNOSTICS", the operator can examine engine diagnostic
data such as fault data, trend, mission analysis, pilot request data, engine operational
data and the real time display.
|
| (5) | The display will ask to select the EEC from the left (port) or right (starboard) engine. |
| (6) | The selection menu will now appear and offer 9 options. The cursor is automatically
positioned at "PROPULSION DISK DOWNLOAD" option. The 9 options are as follows:
|
| (1) | Select "PROPULSION DISK DOWNLOAD" from the selection menu.
NOTE: Follow instructions on the MFD screen for downloading data.
|
| (2) | For menu selection during downloading refer to (Figure , Downloading EDU Data). |
| (3) | The system will download on the diskette and will indicate when the operation is complete.
NOTE: Download may take up to 20 minutes per engine.
|
| (1) | Return to the main selection menu using the TFC menu key and move the cursor down
or up to the "ENGINE OPERATIONAL DATA" menu using DCP keys and press the key to select.
This option will display the following three menu selections of operational data
on the MFD:
|
| (2) | The Flight Data selection displays the following information:
|
| (3) | The Operational Data selection displays the following information:
|
| (4) | The Accumulated Data selection displays the following information:
|
| (1) | Return to the main selection menu using the TFC menu key and select the "PROPULSION FAULT DATA" menu by moving the cursor down or up then use the key to select. |
| (2) | There are 3 possible menus from that option:
|
| (3) | By moving the cursor to the appropriate timestamp and selecting it, details of engine
parameters, continuous data and discretes will be displayed (Ref. Fig. - Standard Parameter Lists, Propulsion Fault Data).
NOTE: The data shown on the MFD screen are extracted from the snapshot recording corresponding
to the selected fault code.
|
| (4) | Up to 10 pages of fault data can be displayed, starting with the latest codes. When no fault has occurred, the following message will be displayed "NO OCCURRENCE OF FAULT DATA". |
| (1) | Select the "ENGINE EXCEEDANCE DATA" menu by moving the cursor down or up then use the key to select. |
| (2) | If any of the following parameter's (ITT, N1, N2, Take Off Duration, Oil Temperature and Oil Pressure) red line limit is exceeded, the EDS will send an exceedance message on the EICAS display. |
| (3) | The message will only be displayed when the aircraft is on the ground to warn the operator to check the EDS. |
| (4) | The maximum number of exceedances shall be three pages, starting with the most recent exceedance. |
| (5) | By moving the cursor to the appropriate time stamp and then selecting it, the 4 pages of the Standard Parameter List will be displayed (Ref. Fig. - Standard Parameter Lists, Propulsion Fault Data). |
| (6) | If there are no faults stored in the fault history log the following message will be displayed: "NO OCCURRENCE OF EXCEEDANCE DATA". |
| (1) | Select the "TREND ANALYSIS DATA" menu by moving the cursor down or up then use the key to select. |
| (2) | For the operator who wishes to use ECTM, engine data is automatically captured by the EDS. A snapshot is taken at max cruise altitude, once the engine parameters have stabilized. |
| (3) | The operator can view up to the latest 10 records. |
| (4) | The EDS shall display a list of the most recent trend recordings. The operator shall be able to view the 10 most recent trend recordings. When the operator selects a trend recording, the EDS shall display the standard parameter list. |
| (5) | If there are no trend recordings stored, the EDS shall display: NO OCCURRENCE OF TREND DATA. |
| (1) | Return to the main selection menu using the TFC menu key and select the "PILOT REQUEST DATA" menu by moving the cursor down or up and use the key to select. |
| (2) | This option will display the engine data that was recorded when the EDS record switch is activated. |
| (3) | This will allow the pilot or technician to request data recording of engine parameters into the EDS memory, in case of abnormal engine operation (fluctuation, abnormal loss of power, sudden ITT split, etc.). |
| (4) | The EDS will record 4 minutes before plus one minute after the EDS record switch has been triggered. |
| (5) | By moving the cursor to the appropriate time stamp and then selecting it, the operator will see the 4 pages of the Standard Parameter List (See Ref. - Propulsion Fault Data). |
| (6) | A list of the 10 most recent pilot request events shall be presented to the user. If no pilot event requests are avaiable, the EDS will display: "NO PILOT REQUEST DATA AVAILABLE". |
| (1) | Return to the main selection menu using the TFC menu key and select the "ON-GROUND EEC DATA" menu by moving the cursor down or up. |
| (2) | This option will assist the operator in engine troubleshooting by displaying real time engine parameters, status words and fault codes. Live EEC data is displayed. The screen is continuously refreshed, to show real time data. |
| (3) | There are two options from this menu:
|
| (4) | In maintenance mode, continuous data from the selected EEC will be shown. In flight mode, data from both engines will be displayed on EICAS. |
| (5) | The "Fault Summary" menu provides real time display of fault codes for better understanding
of the warning indicators for quick fault isolation..
NOTE: In this menu, both channels of one engine are displayed.
|
| (6) | The "Real Time Display" menu of engine parameters can be used for maintenance activities
requiring continous feedback such as TLA rigging.
NOTE: In this menu, both engines lane in control are displayed.
|
| (1) | Download all data per Para. |
| (2) | Remove connector P36 (1) using soft jawed pliers (PWC90012 or Glenair TG69) or Mini strap wrench (PWC58104 or Glenair TG70). |
| (3) | Install protective caps on connectors J36 (2) and P36 (1). |
| (4) | Remove nut (3) and washer (4) . |
| (5) | Pre-SB25270: Remove four bolts (5) and ground terminal (6) . |
| (6) | Post-SB25270: Remove four bolts (5) , washer (13) and ground terminal (6) . |
| (7) | Remove EDU (7) . |
| (8) | Remove two bolts (8) and nuts (9) . |
| (9) | Remove two bolts (10) and washers (11) . |
| (10) | Remove EDU bracket (12) . |
| (1) | Install EDU bracket (12) with two washers (11) and bolts (10) . |
| (2) | Install two bolts (8) and nuts (9) . |
| (3) | Torque bolts (10) 36 to 40 lb.in. (4.0 to 4.5 Nm). |
| (4) | Torque nuts (9) 27 to 30 lb.in. (3.0 to 3.3 Nm). |
| (5) | Pre-SB25270: Install EDU (7) , ground terminal (6) and four bolts (5) . |
| (6) | Post-SB25270: Install EDU (7) , ground terminal (6) with washer (13) and four bolts (5) . |
| (7) | Install washer (4) and nut (3) on opposite end of EDU ground terminal (7) . |
| (8) | Torque four bolts (5) 36 to 40 lb.in. (4.0 to 4.5 Nm). |
| (9) | Torque nut (3) 32 to 36 lb.in. (3.6 to 4.0 Nm). |
| (10) | Remove protective plugs on connectors J36 (2) and P36 (1). |
| (11) | Install connector P36 (1) to connector J36 (2). |
| (12) |
Tighten the connector P36 using one of the following methods:
CAUTION: SOFT JAWED PLIERS HAVE A DESIGN SLIP TORQUE OF 100 lb.in (11.3 Nm). DO NOT USE STEEL
JAWED PLIERS TO TIGHTEN CONNECTORS
CAUTION: WRENCH ASSEMBLY CONNECTOR HAS A DESIGN SLIP TORQUE OF 100 lb.in. (11.3 Nm).
|
| (15) | Verify and update the aircraft information (Ref. AMM). |
| (1) | The EDU provides an RS-422 channel for communicating with a portable computer (laptop)
that has the PCTS422 program (P/N 3053379).
|
| (10) | PCTS422 Fault Display
|
| (14) | PCTS422 Real Time Display
|
| (18) | PCTS422 Cumulative Operational Data
|
| (21) |
PCTS422 Historical Event Data
|
| (24) | PCTS422 Pilot Request Data
|
| (27) | PCTS422 Installation Configuration Data
|
| (1) | DPHM software is a suite of windows based application used for engine management.
It has four main software components:
|
| (2) | EDU Data Download:
|
| (19) | EDU File Analysis
|
| (27) | ECTM Data Analysis
|
| (29) | Trim Editor:
|
| (50) | EDU File Uploading:
|
| Tool No. | Name |
|---|---|
| PWC37728 | Puller, Chip Detector |
| (1) | Remove three
self-locking nuts (8)
and
washers (7)
holding
oil filter cover (6)
to oil filter housing assembly (1).
NOTE: Whenever oil filter element (4) is being removed for a routine check or as a troubleshooting
aid, the cover (6) should not be drained prior to removal in order to facilitate inspection
of contents.
|
| (2) | Withdraw oil filter cover (6) with oil filter element (4) installed. |
| (3) | Remove retaining ring (2) and withdraw filter element (4). |
| (4) | Discard preformed packings (3) and (5) . |
| (1) | Insert new oil filter element (4) into oil filter cover (6) with the three tangs uppermost and install retaining ring (2) . |
| (2) | Install new preformed packing (3) in oil filter element (4) and new preformed packing (5) in oil filter cover (6). |
| (3) | Install oil filter cover (6) with oil filter element (4). Secure with three washers (7) and self-locking nuts (8) . Torque nuts 32 to 36 lb.in. (3.6-4.0 Nm). |
| (4) | Do an Oil Level Check (Ref. 72-00-00, SERVICING). |
| (1) | Drain oil system (Ref. 72-00-00, SERVICING). |
| (2) | Disconnect airframe cable connector from bypass indicator. |
| (3) | Remove two bolts (8) and withdraw oil pressure differential switch (7) . Discard preformed packings (5) and (6) . |
| (4) | Withdraw spring (4) and oil filter bypass valve (3) . |
| (1) | Position spring (4) in core of bypass valve (3) and insert valve into filter housing (1) with spring end out. |
| (2) | Install new preformed packings (5) and (6) on oil pressure differential switch (7) and install into oil filter housing. Secure with two bolts (8) . Torque nuts 36 to 40 lb.in. (4.1-4.5 Nm). |
| (1) | Remove chip detector (10) from AGB. |
| (2) | Remove and discard preformed packings (8) and (9). |
| (3) | Remove valve housing (7). Remove and discard preformed packing (6). |
| (4) | Remove bolts (4) and washers (2). |
| (5) | Remove adapter (5) with puller (PWC37728). |
| (6) | Remove and discard preformed packing (3). |
| (7) | Remove oil strainer (1). |
| (1) | Install oil strainer (1) into the AGB chip detector boss. |
| (2) | Install packing (6) on the adapter (5). Lubricate the packing (6) with engine oil (PWC03-001). |
| (3) | Install the adapter (5) in the AGB with two washers (2) and bolts (4). Torque bolts 36 to 40 lbf.in. (4.1 - 4.5 Nm). |
| (4) | Install packings (8) on the valve housing (7). Lubricate the packing (8) with engine oil (PWC03-001). |
| (5) | Install the valve housing (7) in the adapter (5). Torque 200 to 225 lbf.in. (22.5 - 25.4 Nm). |
| (6) | Install packing (9) on the chip detector (10). Lubricate the packing (9) with engine oil (PWC03-001). |
| (7) | Install chip detector (10) in the valve housing (7). Torque 90 to 100 lbf.in. (10.1 - 11.2 Nm). |
| (1) | Visually inspect filter as follows:
|
| • | Major - When the weight of the constituent is more than 40% of the total debris weight. |
| • | Minor - When the weight of the constituent is between 10% and 40% of the total debris weight. |
| • | Trace - When the weight of the constituent is less than 10% of the total debris weight. |
| • | Particle - A piece of metal less than 0.010 inch in size. |
| • | Chip - A particle larger than 0.010 inch. |
| • | Flake - An extremely thin metal chip. |
| • | Sliver - Thread-like piece of metal. |
| • | Fuzz or Powder - A mass of very fine and light particles. |
| (1) | Inspection and Classification - Visually inspect debris with magnifying glass and/or
microscope, as follows:
|
| (12) | Non-Magnetic Materials - Debris most frequently found in the oil filter include:
|
| (34) | Debris analysis must be done by approved laboratories; refer to Service Information Letter No. GEN-123 for the list of approved oil laboratories. |
| (35) | Table lists material specifications and locations for engine components. |
| (1) | Remove oil filter element from engine. |
| (2) | Seal inner cavity of filter element with suitable tapered plugs. |
| (3) | Place filter in cylindrical container. |
| (4) | Fill container with solvent (PWC11-048), enough to cover filter element but leaving a space for liquid movement when shaking, and install cover. |
| (5) | Shake container for about three minutes manually, or 30 seconds in a vibrator. |
| (6) | Remove cover. Make sure there are no deposits left on filter. If there is, install container cover and continue shaking. |
| (7) | Install new filter patch (PWC05-190) in filter patch holder and place over a suitable container 0.5 gal (2 liters) min. |
| (8) | Remove filter element from container. |
| (9) | Pour liquid contents of container into filter patch holder. |
| (10) | Flush out all possible loose particles which may still be in container by pouring some solvent (PWC11-048) into it, shaking, then emptying into filter patch holder. |
| (11) | Remove filter patch from filter patch holder and place in patch receptacle. Identify sample with type of filter, engine serial number and flight hours run. |
| (12) | If any debris is found, particles large enough to be trapped by filter patch, should
be sent to laboratory for material spectrographic analysis.
NOTE: Some operators retain the filter patches to establish a visual coloration trend.
Operators doing this, need to build up their own experience for patch coloration trend
evaluation because trends may vary from one engine to another and may be affected
by the operating environment and maintenance practices.
|
| (13) | Remove plugs from filter element. Make sure the preformed packing does not drop inside the element). |
| (14) | Dry filter element with clean compressed air at 29 psi (200 kPa). |
| (15) | Install filter element on engine (Ref. Removal/Installation). |
| (1) | Confirmed oil filter bypass requires engine removal.
NOTE: An assessment of the amount of contamination can indicate whether a bypass has actually
occurred. If the oil filters are replaced at regular intervals and debris is found
deposited on most of the filter element surface, associated housing, chip detector
and strainer, it can be considered that a bypass has occurred.
|
| (2) | Remove and inspect chip detector and filters. Use a magnet and determine if any of the debris collected is magnetic. If magnetic debris is found, use a magnifying glass and inspect. Analysis debris and take action required (Ref. Subpara. ). |
| (3) | Do a patch-making procedure (Ref. Subpara. ) on relevant filter and transfer any debris from chip detector (Ref. Subpara. ). Send filter patch and/or tape with chip detector debris for laboratory analysis (Ref. Subpara. ) |
| (4) | If allowable debris is found (Ref. Subpara. , , ), clean and install the chip detector again. Inspect the pressure filter (Ref. Subpara. , ) and again install or replace as required. The aircraft may be returned to normal operation. |
| (5) | If non-allowable debris Category 1 is found (Ref. Subpara. , , ), remove the engine. |
| (6) | If non-allowable debris Category 2 or 3 is found (Ref. Subpara. , , or ), and the engine has no history of generating debris within 400 flight hours, proceed
as follows:
|
| (25) | If non-allowable debris Category 2 or 3 is found (Ref. Subpara. , , or ), and the engine has a history, within 400 flight hours, of generating debris, proceed
as follows:
|
| (1) | Remove chip detector. |
| (2) | Dip magnet end in solvent (PWC11-027) to remove oil. |
| (3) | Transfer debris at magnet end to clear adhesive tape. |
| (4) | Identify tape with engine serial number and hours run since new or overhauled. |
| (5) | Send debris for analysis (Ref. Subpara. ) |
| (6) | Install chip detector. |
| (1) | Wash parts in clean petroleum solvent (PWC11-027). If necessary, use a nylon bristle brush to remove contaminants. |
| (2) | Dry parts using clean, dry, filtered compressed air blast, or allow parts to stand and air dry. |
| (1) | Drain oil system (Ref. 72-00-00, SERVICING). |
| (2) | Remove three nuts (4) , washers (3) , bracket (9) and bolt (10) . |
| (3) | Pre-SB25260: Remove four bolts (6) and bracket (11) from fuel transfer tubes (7) to fuel/oil heat exchanger (8) . |
| (4) | Post-SB25260: Remove four bolts (6) , bracket (11) and three washers (12) from fuel transfer tubes (7) to fuel/oil heat exchanger (8) . |
| (5) | Disengage fuel pressure transfer tubes (7) from the heat exchanger bosses and remove heat exchanger from engine. Discard preformed packings (5) . Remove transfer tubes (2) and discard preformed packings (1) . |
| (6) | Install protective caps and/or plugs in all openings. |
| (1) | Remove all protective caps and/or plugs. |
| (2) | Install new preformed packings (1) and (5) on transfer tubes (2) and (7) . |
| (3) | Insert transfer tubes (2) into oil manifold. |
| (4) | Install heat exchanger (8) on the mounting flange two studs and secure with two washers (3) and nuts (4) . Install bolt (10) , washer (3) and bracket (9) on the mounting flange. Torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (5) | Pre-SB25260: Insert fuel transfer tubes (7) into bosses on heat exchanger (8) . Install bracket (11) and four bolts (6) . Torque 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Post-SB25260: Insert
fuel transfer tubes (7)
into bosses on
heat exchanger (8)
. Install
bracket (11)
, three
washers (12)
and four
bolts (6)
. Torque 36 to 40 lb.in. (4.0-4.6 Nm).
NOTE: Orientation of the bracket is with the long tab on the flange.
|
| (7) | Refer to Chapter 71-00-00 for checks following installation of fuel/oil heat exchanger. |
| (1) | Remove two nuts (6) , bolts (1) and loop clamps (4) securing scavenge oil return tube assembly (3) to intermediate case brackets (5) . |
| (2) | Remove two bolts (1) at flange on top of intermediate case and two bolts (1) at the gearbox mounting boss and remove scavenge oil return tube assembly (3). |
| (3) | Remove and discard preformed packings (2) , (7) . Place protective covers on tube (3). |
| (1) | Lubricate two new preformed packings (2) , (7) with engine oil (PWC03-001) and install on scavenge oil return tube assembly (3) . |
| (2) | Install scavenge oil tube (3) to boss on intermediate case, and to the accessory gearbox mounting boss and secure with four bolts (1) . Torque two bolts at the intermediate case boss 36 to 40 lb.in. (4.1-4.5 Nm) and torque two bolts at the accessory gearbox area 36 to 40 lb.in. (4.1-4.5 Nm). |
| (3) | Install two loop clamps (4) on scavenge oil tube (3) and secure to the brackets (5) , and secure with two bolts (1) and nuts (6) . Torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Remove nut (10) , bolt (14) and loop clamp (11) securing No. 4 bearing scavenge oil tube assembly (15) to bracket on Flange E. |
| (2) | Remove bolt (34) and nut (35) to disconnect the loop clamp (33) from the bracket of the primary fuel tube (36). |
| (3) | Remove nut (10), bolt (14) and remaining loop clamp (11). |
| (4) | Remove two bolts (13) at outer bypass duct and two nuts (10) and bolts (13) at flange on elbow (29) and remove No. 4 bearing scavenge oil tube assembly (15) and gasket (8) . Discard gasket. |
| (5) | Remove four preformed packings (9) , (12) . Discard preformed packings. Place protective covers on tube ends. |
| (1) | Lubricate two new preformed packings (9) with engine oil (PWC03-001) and install on elbow (29). Install new metal gasket (8) on elbow (29). |
| (2) | Lubricate two new preformed packings (12) and install on No. 4 bearing scavenge oil tube assembly (15) . |
| (3) | Install No. 4 bearing scavenge oil tube (15) to elbow (29) with two bolts (13) and nuts (10) . Torque nuts 27 to 30 lb.in. (3.0-3.4 Nm). |
| (4) | Secure lower end of oil tube assembly (15) to outer bypass duct with two bolts (13). Torque bolts 20 to 30 lb.in. (2.2-3.4 Nm). |
| (5) | Secure oil tube assembly (15) to bracket on flange E with loop clamp (11) , bolt (14) and nut (10). Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (6) | Secure oil tube assembly (15) to bracket on pressure oil tube assembly with bolt (14) and nut (10). Torque nut (10) and nut (17) 27 to 30 lb.in. (3.0-3.4 Nm). |
| (7) | Secure loop clamp (33) of scavenge oil tube to bracket on the primary fuel tube (36) using bolt (34) and nut (35). Torque 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Remove nut (10) , bolt (13) and loop clamp (19) . |
| (2) | Remove two bolts (17) . Remove lockwire and remove two bolts (22) and scavenge oil tube assembly (20) . |
| (3) | Remove and discard preformed packings (21) , (28) . Place protective covers on tube ends. |
| (1) | Lubricate two new preformed packings (16) , (21) with engine oil (PWC03-001) and install on No. 4 bearing scavenge oil tube assembly (20) . |
| (2) | Install scavenge oil tube assembly (20) to boss on accessory gearbox and secure with two bolts (17) , and to boss on outer bypass duct and secure with two bolts (22) . Torque bolts (17) 36 to 40 lb.in. (4.0-4.6 Nm), and bolts (22) 20 to 30 lb.in. (2.2-3.2 Nm). |
| (3) | Install loop clamp (19) on tube assembly (20) and secure to loop clamp (32) with bolt (30) and nut (31) . Torque nut 27 to 30 lb.in. (3.0-3.4 Nm). |
| (1) | Remove two bolts (17) and washers (24) , securing elbow (2) to boss on outer bypass duct. |
| (2) | Remove elbow (25) and transfer tube (27) as an assembly. Remove and discard preformed packings (16) , (23) . |
| (3) | Remove retaining ring (26) and separate transfer tube (27) from elbow (25). Remove and discard preformed packing (16). Place protective covers on tube ends. |
| (4) | Remove lockwire and disconnect coupling nut on differential pressure switch tube assembly from scavenge oil tube assembly (18) . |
| (5) | Remove four bolts (17) and scavenge oil tube assembly (18). Remove and discard preformed packing (16). Place protective covers on tube ends. |
| (1) | Lubricate new preformed packing (28) and install on scavenge oil tube assembly (18) . |
| (2) | Install scavenge oil tube (18) on accessory gearbox and secure at two places with four bolts (17) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (3) | Place retaining ring (26) over transfer tube (27) . |
| (4) | Lubricate two new preformed packings (16) and install on transfer tube (27). |
| (5) | Install transfer tube (27) in elbow (25) . Do not secure with retaining ring (26) at this time. |
| (6) | Lubricate new preformed packing (23) and install on elbow (25). |
| (7) | Install elbow (25) on bypass duct boss and secure with two washers (24) and bolts (17). Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (8) | Slide transfer tube (27) into scavenge oil tube (18) and engage retaining ring (26) in elbow (25). |
| (9) | Connect coupling nut of differential pressure switch tube assembly (Ref. 79-30-02) to tee connection of scavenge oil tube (18). Torque coupling nuts of tube 90 to 100 lb.in. (10-11 Nm) and lockwire (PWC11-021). |
| (1) | Cracks - Cracked tubing must be replaced. No repair is permitted. |
| (2) | Scratches - Minor scratches having no appreciable depth are acceptable. Scratches to a depth of 0.005 inch (0.13 mm) must be blended out. Replace tubing with scratches over 0.005 inch (0.13 mm) inch deep. |
| (3) | Nicks - Individual nicks up to 0.062 inch (11.58 mm) long by 0.010 inch (0.25 mm) wide and 0.003 inch (0.08 mm) deep can be ignored. Nicks to a maximum depth of 0.005 inch (0.13 mm) must be blended out to remove sharp edges. Replace tubing with nicks greater than 0.005 inch (0.13 mm) deep. |
| (4) | Dents - Round bottom dents on straight sections of tubing are permitted provided the length and depth are not greater than 10 percent of the normal outside diameter of tube. No more than one dent to maximum depth per 12 inch (30.5 cm) length of tube is acceptable. Dents on tube bends, which cause restriction by flattening and local weakening, are not acceptable. |
| (5) | Pitting - Minor isolated pitting up to 0.003 inch (0.08 mm) deep is acceptable. Clusters of pitting should be blended out to a maximum depth of 0.005 inch (0.13 mm). Tubing must be replaced if pitting exceeds 0.005 inch (0.13 mm) deep. |
| (6) | Corrosion - Straining on tubing and surface corrosion is acceptable if removable by light polishing with crocus cloth and oil. |
| (1) | Soak external oil tubing in cold carbon remover compound (PWC11-021) for two hours at room temperature. |
| (2) | Remove tube from solvent and pull a suitable sized swab (or lint-free cloth) through tube. |
| (3) | Rinse tube exterior with petroleum solvent. |
| (4) | Pressure flush tube interior with petroleum solvent (PWC11-027) and dry interior and exterior with compressed air. |
| (1) | Remove nut (5) and bolt (6) fastening loop clamp (4) to adjacent P3 air tube bracket. |
| (2) | Remove coupling nut of tube (3) from MOT sensor fitting. |
| (3) | Remove two bolts (2) at the upper end of the tube and remove tube. |
| (4) | Remove and discard preformed packing (1) . |
| (1) | Lubricate new preformed packing (1) with engine oil (PWC03-001), and install on tube assembly (3) . |
| (2) | Lubricate two bolts (2) with engine oil (PWC03-001). Install tube (3) to boss on intermediate case with two bolts (2). Do not tighten. |
| (3) | Install coupling nut of tube (3) to the MOT sensor fitting. Tighten coupling nut 400 to 450 lb.in. (45.2-51.0 N.m), while holding MOT tube with wrench. |
| (4) | Tighten bolts (2) 36 to 40 lb.in. (4.1-4.6 Nm.). |
| (5) | Install loop clamp (4) on tube (3) and fasten to adjacent P3 air tube bracket with nut (5) and bolt (6) . Tighten nut 36 to 40 lb.in. (4.1-4.6 Nm.) |
| (1) | Remove bolts (13) from nutplates (9) , five places, and disengage the wiring harness loop clamps (4) from tube (1) . |
| (2) | Remove two bolts (12) fastening loop clamps (11) to flange brackets (10) , two places (Ref. Detail A). Remove loop clamps from tube (1). |
| (3) | Remove bolt (8) and nut (5) fastening spacer (7) and loop clamp (6) to adjacent wiring harness loop clamp. Remove loop clamp from tube. |
| (4) | Remove lockwire and coupling nut at lower end of tube (1), from AGB oil tube. |
| (5) | Remove bolts (2) and oil tube (1). |
| (6) | Remove and discard preformed packing (3) . |
| (1) | Lubricate new preformed packing (3) with engine oil (PWC03-001), and install on tube assembly (1) . |
| (2) | Install tube assembly (1) to boss on intermediate case with two bolts (2) . Do not tighten bolts. |
| (3) | Connect coupling nut at lower end of tube assembly (1) to AGB tube. Tighten coupling nut 450 to 500 lb.in. (50.0-56.0 N.m) and bolts (2) 36 to 40 lb.in. (4.0-4.5 N.m). |
| (4) | Install loop clamps (11) on tube and fasten to flange brackets (10) with bolt (12) , two places (Ref. Detail A). Tighten bolt 36 to 40 lb.in. (4.01-4.5 N.m) at each location. |
| (5) | Install loop clamp (6) on tube assembly (1). |
| (6) | Install spacer (7) between wiring harness loop clamp and oil tube loop clamp (6) and fasten together with nut (5) and bolt (8) . Tighten bolt 36 to 40 lb.in. (4.0-4.5 N.m). |
| (7) | Install wiring harness loop clamps (4) to nutplates (9) with bolts (13) , five places. Tighten bolt 36 to 40 lb.in. (4.0-4.5 N.m) at each location. |
| (1) | Remove bolt (3) and nut (5) fastening loop clamp (4) to adjacent scavenge oil tube loop clamp. |
| (2) | Remove two bolts (14) fastening tube (15) at the boss on the outer bypass duct. |
| (3) | Remove lockwire and coupling nut (16). Disconnect the other end of the tube (15) from AGB pressure oil tube assembly (8) . Remove the oil tube (15). |
| (4) | Remove and discard preformed packing (13) . |
| (1) | Lubricate new preformed packing (13) with engine oil (PWC03-001), and install on oil tube assembly (15) . |
| (2) | Install tube assembly (15) to boss on outer bypass duct with two bolts (14) . Tighten bolts fingertight. |
| (3) | Install coupling nut (16) of pressure oil tube assembly (15) to AGB oil pressure tube assembly (8) . Tighten coupling nut fingertight (16). |
| (4) | Install loop clamp (4) on tube (15) and fasten to adjacent loop clamp with nut (5) and bolt (3) . Tighten nut |
| (5) | Tighten bolts (14) 36 to 40 lb.in. (4.0-4.5 N.m) and install lockwire (PWC05-089). |
| (6) | Hold AGB pressure oil tube assembly (8) and tighten coupling nut (16) 90 to 100 lb.in. (10.0-11.0 N.m) and install lockwire (PWC05-089). Tighten bolts (15) 36 to 40 lb.in. (4.0-4.6 N.m). |
| (1) | Remove two bolts (7) and AGB oil pressure tube assembly (8) . |
| (2) | Remove and discard preformed packing (9) . |
| (1) | Lubricate new preformed packing (9) with engine oil (PWC03-001), and install on oil tube (8) . |
| (2) | Install tube (8) to boss on AGB with two bolts (7) . Tighten bolts 36 to 40 lb.in. (4.0-4.6 N.m). |
| (1) | Cut lockwire connecting tube assembly (10) with anti-syphon pressure oil tube assembly. |
| (2) | Remove bolts (11) and disconnect tube (10). |
| (3) | Remove nut (6) and bolt (1) fastening loop clamp (2) to adjacent oil tube loop clamp. Remove loop clamp (2) from tube (10) |
| (4) | Remove and discard preformed packing (12) . |
| (1) | Lubricate new preformed packing (12) with engine oil (PWC03-001), and install on tube (10) . |
| (2) | Install tube assembly (10) to boss with bolts (11) . Tighten bolts 36 to 40 lb.in. (4.0-4.5 N.m). |
| (3) | Lockwire coupling nut of anti-syphon pressure oil tube assembly. |
| (4) | Install loop clamp (2) on tube (10) and fasten to adjacent tube with nut (6) and bolt (1) . Tighten nut 27 to 30 lb.in. (3.0-3.4 N.m). |
| (1) | Remove nut (10) , bolt (11) fastening loop clamp (1) to flange bracket. Remove loop clamp from tube (5) |
| (2) | Remove nut (8) , bolt (3) and loop clamp (7) from oil tube assembly (5). |
| (3) | Remove nut (13) , bolt (2) and loop clamp (4) from bracket (12) . |
| (4) | Remove two nuts (15) and (16) and bolts (18) and (20) at elbow (17). |
| (5) | Remove two bolts (6) at tube connection to outer bypass duct, and remove pressure tube assembly (5). |
| (6) | Remove and discard gasket (19) and preformed packings (9) and (14) . |
| (1) | Lubricate two new preformed packings (14) with engine oil (PWC03-001) and install on elbow (17). |
| (2) | Install new gasket (19) on elbow (17). |
| (3) | Lubricate two new preformed packings (9) with engine oil (PWC03-001) and install on tube (5) . |
| (4) | Install oil tube assembly (5) on elbow (17) with two bolts (18) and (20) and nuts (15) and (16) . Tighten nuts 27 to 30 lb.in. (3.0-3.4 N.m). |
| (5) | Connect remaining end of oil tube assembly (5) on boss on outer bypass duct with two bolts (6) . Tighten bolts 27 to 30 lb.in. (3.0-3.4 N.m). |
| (6) | Install loop clamp (1) on oil tube assembly (5) and fasten to bracket on flange with bolt (11) and nut (10) . Tighten nut 27 to 30 lb.in. (3.0-3.4 N.m). |
| (7) | Install loop clamp (7) on tube (5) and fasten to adjacent fuel tube bracket with bolt (3) and nut (8) . Tighten nut 27 to 30 lb.in. (3.0-3.4 N.m). |
| (8) | Install loop clamp (4) on oil tube assembly (5) and fasten to bracket (12) with bolt (2) and nut (13) . Tighten nut fingertight. |
| (1) | Cracks - Cracked tubing must be replaced. No repair is permitted. |
| (2) | Scratches - Minor scratches having no appreciable depth are acceptable. Scratches to a depth of 0.005 inch (0.13 mm) must be blended out. Replace tubing with scratches over 0.005 inch (0.13 mm) inch deep. |
| (3) | Nicks - Individual nicks up to 0.062 inch (11.58 mm) long by 0.010 inch (0.25 mm) wide and 0.003 inch (0.08 mm) deep can be ignored. Nicks to a maximum depth of 0.005 inch (0.13 mm) must be blended out to remove sharp edges. Replace tubing with nicks greater than 0.005 inch (0.13 mm) deep. |
| (4) | Dents - Round bottom dents on straight sections of tubing are permitted provided the length and depth are not greater than 10 percent of the normal outside diameter of tube. No more than one dent to maximum depth per 12 inch (30.5 cm) length of tube is acceptable. Dents on tube bends, which cause restriction by flattening and local weakening, are not acceptable. |
| (5) | Pitting - Minor isolated pitting up to 0.003 inch (0.08 mm) deep is acceptable. Clusters of pitting should be blended out to a maximum depth of 0.005 inch (0.13 mm). Tubing must be replaced if pitting exceeds 0.005 inch (0.13 mm) deep. |
| (6) | Corrosion - Staining on tubing and surface corrosion is acceptable if removable by light polishing with crocus cloth and oil. |
| (1) | Soak external oil tubing in cold carbon remover compound (PWC11-021) for two hours at room temperature. |
| (2) | Remove tube from solvent and pull a suitable sized swab, or lint-free cloth through tube. |
| (3) | Rinse tube exterior with solvent (PWC11-027). |
| (4) | Pressure flush tube interior with solvent (PWC11-027). |
| (5) | Dry interior and exterior with dry, compressed air. |
| Item No. | Name | Remarks |
|---|---|---|
| PWC03-001 | Oil, Engine Lubricating |
| Tool No. | Name |
|---|---|
| PWC43172 | Puller |
| PWC60831 | Fixture |
| PWC64241-2 | Guide Pin |
| PWC90000 | Heat Gun |
| (1) | Drain oil system (Ref. Chapter 72-00-00, ENGINE, SERVICING). |
| (2) | Remove EEC and lower electrical bracket assembly (Ref. Chapter 73-20-02, ELECTRONIC ENGINE CONTROL (EEC) - MAINTENANCE PRACTICES). |
| (3) | Remove two bolts (3) , retaining plate (2) and slide tube (15) into oil pump (6) . |
| (4) | Remove four bolts (12) , washers (11) and remove oil pump assembly (6). |
| (5) | Remove transfer tube (5) and discard preformed packing (4) . |
| (6) | Remove transfer tube (15) from oil pump assembly (6) and discard preformed packings (14) . |
| (7) | Remove two retaining rings (1) and withdraw strainer element (17) from transfer tube (15). |
| (8) | If necessary, remove nuts (10) , washers (9) , cover (8) and preformed packing (7) . Discard preformed packing. |
| (1) | Lubricate preformed packing (7) with engine oil (PWC03-001), install on cover (8) and install cover with washers (9) and nuts (10) . Torque nuts 23 to 26 lb.in. (2.6-3.0 Nm.). |
| (2) | Install strainer element (17) in transfer tube (15) with two retaining rings (1) . |
| (3) | Lubricate preformed packings (4) with engine oil (PWC03-001), install on transfer tube (5) and install tube (5) into oil pump assembly. |
| (4) | Lubricate preformed packings (14) with engine oil (PWC03-001), on transfer tube (15) and install tube (15) into main oil supply port of oil pump assembly (6) . |
| (5) | Lubricate preformed packing (16) with engine oil (PWC03-001), and install on oil pump assembly (6). |
| (6) | Install one guide pin (PWC64241-2) on the AGB at the oil pump bolt hole location.
NOTE: Use of assembly fluid is permitted to hold the guide pin in place.
|
| (7) | Set the dial of heat gun (PWC90000) to #3. Evenly heat the AGB bore in a circular motion for 5 to 10 minutes. |
| (8) |
Align guide pin, transfer tubes (15 and 5) and coupling shaft to install oil pump
(6) on the AGB.
NOTE: The starter shaft may require rotating to align with the coupling shaft.
|
| (9) | Remove the guide pin and install four bolts (12) with washers (11) . Torque bolts in a star pattern 36 to 40 lb.in. (4.0-4.6 Nm.). |
| (10) | Push transfer tube (15) into the intermediate case and secure with retaining plate (2) and two bolts (3) . Torque 36 to 40 lb.in. (4.0-4.6 Nm.). |
| (11) | Install the lower electrical bracket assembly and the EEC (Ref. Chapter 73-20-02, ELECTRONIC ENGINE CONTROL (EEC) - MAINTENANCE PRACTICES). |
| (12) | Replenish the oil system (Ref. Chapter 72-00-00, ENGINE, SERVICING). |
| (13) | Do the required engine checks following installation of the oil pump (Ref. 71-00-00,
POWER PLANT - ADJUSTMENT/TEST).
NOTE: Adjust oil pressure as necessary.
|
| (1) | Drain the engine oil from the oil tank (Ref. 72-00-00, SERVICING). |
| (2) | Remove the two nuts (9) , the two bolts (1) and the two washers (12). Remove the valve cover (10) with puller (PWC43172). |
| (3) | Remove and discard preformed packing (11) . |
| (4) | Remove PAV and cold start valve by turning assembly counterclockwise. |
| (5) | Compress seat (7) and spring (6) in the valve (5) with compressor (PWC60831), and remove retaining ring (8) , seat (7), spring (6) and valve (5) from the sleeve (4) . |
| (1) | Assemble PAV and cold start valve as follows:
|
| (6) | Screw in PAV and cold start valve assembly into the valve housing (3) in the oil pump cover until it seats lightly. |
| (7) | Adjust seating by turning the valve 1 turn counterclockwise. |
| (8) | Lubricate preformed packing (11) with engine oil (PWC03-001) and install it on the valve cover (10) . |
| (9) | Install the valve cover (10) with the two bolts (1), the two washers (12) and the two nuts (9). Torque bolts 27 to 30 lbf.in. (3.1-3.3 Nm). |
| (10) | Replenish engine oil (Ref. 72-00-00, SERVICING). |
| (11) | Do the required engine checks following installation of the PAV/cold start valve (Ref.
71-00-00, POWER PLANT - ADJUSTMENT/TEST).
NOTE: Adjust oil pressure as necessary.
|
| (1) | Refer to 72-00-00, SERVICING. |
| (1) | Inspect flats and safety wire holes for excessive wear. |
| (2) | Examine internal and external threads for damage. |
| (3) | Check that electrical connector is securely swaged in housing. |
| (4) | Examine terminals of electrical connector; make sure terminals are clean, secure and undamaged and that potting compound is not cracked. |
| (5) | Before doing a continuity check after a chip detector fault code event or a chip detector
event, clean the electrical pin and magnet area as follows, to make sure that the
chip detector is free of any contamination:
|
| (9) | Connect ohmmeter across detector output terminals and place suitable iron bar across magnetic poles. Circuit continuity must exist. Remove bar and check that open circuit is indicated. |
| (10) | Check that continuity resistance between each connector terminal and corresponding magnet is less than 0.5 ohms. |
| (11) | Check that insulation resistance between magnets and between either magnet and body is 10 megaohms minimum at 68°F (20°C). |
| (12) | Test magnetic poles using suitable steel weight. A minimum weight of six ounces must be lifted by the poles. |
| (13) | If components are unserviceable, the magnetic chip detector assembly must be replaced. |
| (1) | Inspect flats and safety wire holes for excessive wear. |
| (2) | Examine internal and external threads for damage. |
| (3) | Examine valve and valve chamber for scoring or other damage. |
| (4) | Check that bent leg of spring is undamaged and retains spring in housing. |
| (5) | If components are unserviceable, the magnetic chip detector assembly must be replaced. |
| Item No. | Name |
|---|---|
| PWC05-089 | Lockwire |
| (1) | Disconnect airframe connections from oil tube assembly (8) , air tube assembly (11) and switch (1) . |
| (2) | Remove self-locking nut (14) , bolt (17) , self-locking nut (16) , bracket (15) and loop clamp (18) . |
| (3) | Remove lockwire and disconnect coupling nuts (10 and 2). |
| (4) | Remove air tube assembly (11). |
| (5) | Remove self-locking nut (12) , loop clamp (13) and washer (5). |
| (6) | Remove lockwire and disconnect coupling nuts (9 and 4). |
| (7) | Remove oil tube assembly (8). |
| (8) | Remove self-locking nuts (3) and (19) , switch (1) and two spacers (5) . |
| (1) | Position two spacers (5) on fuel filter housing (6) . |
| (2) | Position switch (1) on spacers (5) and fasten with self-locking nuts (19) and (3) . Torque 23 to 26 lb.in. (2.6-2.9 Nm). |
| (3) | Position oil tube assembly (8) on switch (1). Tighten coupling nuts (4) and (9) with your hand. |
| (4) | Position washer (7) on fuel filter housing (6). Install loop clamp (13) on oil tube assembly (8) with self-locking nut (12) . Torque 23 to 26 lb.in. (2.6-2.9 Nm). |
| (5) | Torque coupling nuts (9) and (4) 90 to 100 lb.in. (10.2-11.3 Nm). |
| (6) | Position air tube assembly (11) on switch (1) and tighten coupling nuts (10) and (2) with your hand. |
| (7) | Position loop clamp (18) on air tube assembly (11). |
| (8) | Install bracket (15) on fuel filter housing (6) with self-locking nut (16) . Torque 23 to 26 lb.in. (2.6-2.9 Nm). |
| (9) | Install loop clamp (18) to bracket (15) with bolt (17) and self-locking nut (14) . Torque 23 to 26 lb.in (2.6-2.9 Nm). |
| (10) | Torque coupling nuts (10) and (2) 90 to 100 lb.in. (10.2-11.3 Nm) and install lockwire (PWC05-089). |
| (11) | Connect airframe connections to oil tube assembly (8), air tube assembly (11) and switch (1). |
| (1) | Remove the electrical connector (Ref. Aircraft Maintenance Manual). |
| (2) | Cut lockwire of the two coupling nuts (3, 6) and disconnect the two ends of tube assembly from the transducer. |
| (3) | Remove the two mounting bolts (5) , nuts (8) and washers (9) from the bracket (1) on the intermediate case. |
| (4) | Remove the two mounting clamps (4) and remove the transducer (2) . |
| (1) | Install the two mounting clamps (4) and position the transducer (2) on the mounting bracket (1). Secure with bolts (5) , washers (9) and nuts (8) . Torque nuts to 36 to 40 lb.in. (4.1-4.5 Nm). |
| (2) | Install the two coupling nuts (3, 6) on the transducer body. Tighten the nuts fingertight. |
| (3) | Torque two coupling nuts (3, 6) 90 to 100 lb.in. (10.0-11.5 Nm) and lockwire (PWC05-089). |
| (4) | Install the electrical connector (Ref. Aircraft Maintenance Manual). |
| Tool No. | Name |
|---|---|
| PWC60231 | Test Fixture |
| (1) | Remove bolts (4) . |
| (2) | Pre-SB25164 or Pre-SB25206:
|
| (5) | Post-SB25164 or Post-SB25206: Remove cover (5) , gasket (6) , indicator (9) , gasket (2) and float (7) . Discard gasket (2) and gasket (6). |
| (6) | Post-SB25164 or Pre-SB25206: Remove and discard rivet (8) . |
| (7) | Post-SB25206: Remove pin (10) . |
| (1) | Wipe a thin coat of assembly fluid (PWC06-011) on the surface of oil level indicator reflector (1, Fig. ) which is in contact with the oil filler neck assembly. |
| (2) | Install reflector (1) and float (7) . |
| (3) | Lubricate bolts (4) with engine oil (PWC03-001) and install gasket (2) , glass (3) , gasket (6) , cover (5) and bolts. |
| (4) | Torque bolts (4) in increments of 5 lb.in. (0.6 Nm) to a torque of 25 to 30 lb.in. (2.8-3.4 Nm) in sequence as shown (Ref. Fig. ). |
| (5) | Install lockwire (PWC05-089). |
| (6) | If lockwire holes do not align, do not loosen bolts. Torque bolt(s) to 30 lb.in. (3.4 Nm) maximum, and install lockwire. If bolts are loosened more than 10 lb.in. (1.1 Nm) gaskets (2 and 6) must be replaced. |
| (1) | Insert the float (7) through the oil exit opening in the oil filler neck. Make sure the float passes through the sight glass chamber into the throat area chamber. |
| (2) | Pre-SB25206: Secure the oil filler neck assembly in a bench vise with the sight glass opening facing up. Install the rivet (8) at the location shown. |
| (3) | Post-SB25206: Secure the assembly in a bench vise with the sight glass opening facing up. Install the pin (10) at the location shown. |
| (4) | Install the gasket (2) in the sight glass seat. |
| (5) | Install the indicator (9) with the plain glass face out and the fluted face to the oil chamber. |
| (6) | Install gasket (6) and cover (5) with bolts (4) . |
| (7) | Torque bolts (4) in increments of 5 lb.in (0.6 Nm) to a torque of 25 to 30 lb.in (2.8-3.4 Nm) in sequence as shown (Ref. Fig. ). |
| (8) | Install safety cable (PWC05-344). If safety cables holes do not align, do not loosen bolts. Torque bolts to 30 lb.in (3.4 Nm) maximum and install safety cable. If bolts are loosened more than 10 lb.in (1.1 Nm) gaskets (2 and 6) must be replaced. |
| (1) | Remove lockwire from oil pressure indicator (4) . |
| (2) | Remove oil pressure indicator (4) from housing (1) . |
| (3) | Remove and discard preformed packings (3) and (2) . |
| (1) | Check function of indicator (Ref. Testing). |
| (2) | Lubricate new preformed packings (3) and (2) with engine oil (PWC03-001) and install on differential oil pressure indicator (4) . |
| (3) | Install oil pressure indicator (4) in housing (1) . Tighten indicator 200 to 225 lb.in. (23-25 Nm) and install lockwire (PWC05-089). |
| (1) | Pre-SB25164 or Pre-SB25206: Note position of sensor (2) . Remove bolts (3) and sensor. |
| (2) | Post-SB25164 or Post-SB25206: Note position of sensor (2) . Remove bolts (3) , bracket (4) and sensor (2). |
| (3) | Remove and discard preformed packing (1) . |
| (1) | Lubricate new preformed packing (1) with engine oil (PWC03-001) and install on the sensor (2). |
| (2) | Pre-SB25164 or Pre-SB25206: Install sensor (2) into the filler neck with bolts (3) . Tighten bolts with fingers. |
| (3) | Post-SB25164 or Post-SB25206: Install sensor (2) into the filler neck with bracket (4) and bolts (3) . Tighten bolts with fingers. |
| (4) | Position sensor (2) in same position as that noted at removal. Torque bolts (3) 36 to 40 lb.in (4.0-4.6 Nm) and install lockwire (PWC05-089). |
| (1) | Take note of the oil level in the sight glass. |
| (2) | With suitable test leads, connect an ohmmeter to pins A and B of the sensor (Ref.
Fig. ). If the oil level can be seen in the sight glass, the sensor switch must read closed
(0-1 ohms).
NOTE: The sensor switch can also read closed when the oil level is below the sight glass,
if the oil level is above the height of the sensor switch.
|
| (3) | Drain the oil tank (Ref. 72-00-00 ENGINE - SERVICING). |
| (4) | When the oil level falls below the sensor, the switch must change from closed to open (10 Megohms minimum). |
| (5) | Remove the oil level sensor (Ref. Para. ). |
| (6) | Connect an ohmmeter to pins A and B of the sensor, with the sensor in the installed position the switch must read open (10 Megohms minimum). |
| (7) | Turn the sensor over, in the inverted position the switch must read closed (0-1 ohms). Lightly tap the sensor in different directions, a sudden change in resistance (greater than 0.5 ohms) shows that the sensor is unserviceable. |
| (8) | Reject and replace the sensor if it is not satisfactory in all of the above checks. |
| (1) | Remove oil level indicator (Ref. Para. ). |
| (2) | Remove oil level sensor (Ref. Para. ). |
| (3) | Remove filler cap (1) . Remove and discard preformed packing (2) . |
| (4) | Pre-SB25164 or Pre-SB25206:
|
| (9) | Post-SB25164 or Post-SB25206:
|
| (16) | Remove retaining ring (19) and strainer element (20) . |
| (1) | Install the strainer element (20) and retaining ring (19) in the filler neck (5) . |
| (2) | Lubricate new preformed packings (3) and (9) with engine oil (PWC03-001) and install on each end of filler neck (5). |
| (3) | Install the filler neck (5) into its mounting points on the intermediate case and engage the upper end tube to the pressure indicator housing. |
| (4) | Install mounting bracket (6) into the filler neck assembly (5) with bolts (7) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (5) | Install the bottom end of the filler neck with bolts (8) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Lubricate new preformed packing (2) with engine oil (PWC03-001), install on filler cap (1) and install filler cap in oil filler neck (5). |
| (7) | Install oil level sensor (Ref. Para. ). |
| (8) | Install oil level indicator (Ref. Para. ). |
| (1) | Install the strainer element (20) and retaining ring (19) in the filler neck (5) . |
| (2) | Lubricate new preformed packing (9) with engine oil (PWC03-001) and install on filler neck (5). |
| (3) | Install the filler neck (5) into its mounting points on the intermediate case and engage the upper end tube to the pressure indicator housing. |
| (4) | Install mounting bracket (6) and bracket (10) onto the filler neck assembly (5) with bolts (7) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (5) | Install the bottom end of the filler neck with bolts (8) . Torque bolts 36 to 40 lb.in. (4.0-4.6 Nm). |
| (6) | Make sure there is a minimum gap of 0.125 inches between the low oil level switch
flange on the filler neck and the oil scavenge tube. This must be achieved with no
adjustment to any other hardware other than those that can be achieved with bolt clearances.
NOTE: This minimum gap is only applicable when the oil filler neck is installed on the
left-hand side of the engine.
|
| (7) | Install new packings (11) and (18) on oil vent tube (12) . Install vent tube (12) and secure with bolts (13) and (17) . Tighten the bolts with fingers. |
| (8) | Centralize the vent tube and torque the upper and lower bolts (13 and 17) 36 to 40 lb.in. (4.0-4.6 Nm) and install safety cable. |
| (9) | Install loop clamp (14) on vent tube at the location shown and attach with bolt (15) and nut (16) . Torque the bolt 36 to 40 lb.in. (4.0-4.6 Nm). |
| (10) | Lubricate new preformed packing (2) with engine oil (PWC03-001), install on filler cap (1) and install filler cap on oil filler neck (5). |
| (11) | Install oil level sensor (Ref. Para. ). |
| (12) | Install oil level indicator (Ref. Para. ). |
| (1) | Remove nut (15) , bolt (14) and clamp (13) from bracket (12) at flange C. |
| (2) | Hold the elbow (4) with a wrench, and remove the coupling nuts at end of tubes (6) and (2) . |
| (3) | Remove bolts (3) fastening flange of tube (2) to intermediate case. |
| (4) | Remove and discard gasket (1) . |
| (5) | Remove bolts (8) fastening flange of tube (6) to oil indicator housing (7) . |
| (6) | Remove and discard preformed packing (5) . |
| (1) | Install gasket (1) on tube (2) . Attach tube (2) with 2 bolts (3) , leave the bolts loose. |
| (2) | Install elbow (4) on tube (2), leave the coupling nut loose. |
| (3) | Install packing (5) on tube (6) . Attach tube (6) into the oil indicator housing (7) and assemble the coupling end to the elbow, leave the coupling nut loose. |
| (4) | Attach tube (6) with 2 bolts (8) . Torque bolts 24 to 30 lb.in. (2.7-3.3 Nm) and lockwire. |
| (5) | Torque bolts (3) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (6) | Torque coupling nuts on tube (6) and elbow (4) 90 to 100 lb.in. (10.1-11.2 Nm).
NOTE: Hold the elbow (4) with a wrench while torquing the coupling nuts.
|
| (7) | Remove bolt (9) washer (10) and nut (11) . Install bracket (12) and reinstall bolt (9) washer (10) and nut (11). Torque bolts to 27 to 30 lb.in. (3.1-3.4 Nm) again. |
| (8) | Install clamp (13) to bracket (12) with bolt (14) and nut (15) . Torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (1) | Remove two nuts (8) , two bolts (16) and two loop clamps (3) from brackets (5) and (6) at flange C. |
| (2) | Remove two nuts (8), two bolts (15) , two washers (2) and brackets (5 and 6). |
| (3) | Remove bolt (16), nut (8) and loop clamp (3) from bracket (4) . |
| (4) | Remove bolt (15) and bracket (4). |
| (5) | Hold the elbow (13) with a wrench, remove the coupling nuts at end of vent tubes (7) and (10) and remove elbow. |
| (6) | Remove two bolts (14) from flange of vent tube (10) at intermediate case. |
| (7) | Remove and discard gasket (11) . |
| (8) | Remove two bolts (1) from flange of vent tube (7) at oil filler neck. Remove vent tube. |
| (9) | Remove and discard preformed packing (9) . |
| (10) | If necessary, Remove filler cap cable (12) and bolt (17) . |
| (1) | Install a new gasket (11) on flange of vent tube (10) . Attach vent tube (10) and gasket (11) to the intermediate case with two bolts (14) , tighten the bolts with your fingers. |
| (2) | Lubricate a new preformed packing (9) with engine oil and install on vent tube (7). |
| (3) | Install vent tube (7) on the oil filler neck with two bolts (1) , tighten the bolts with your fingers. |
| (4) | Install elbow (13) on vent tubes (7 and 10), tighten the coupling nuts with your fingers. |
| (5) | Install brackets (5) and (6) to front of flange C with bolt (15) , washer (2) and nut (8) . Torque bolts 27 to 30 lb.in. (3.1-3.4 Nm). |
| (6) | Install bracket (4) with the short leg on the oil filler neck mounting bracket. Install bolt (15) and torque 36 to 40 lb.in. (4.1-4.5 Nm). |
| (7) | Install loop clamps (3) on brackets (4, 5 and 6) with bolts (16) and nuts (8). Torque bolts 36 to 40 lb.in. (4.1 - 4.5 Nm). |
| (8) | Torque the vent tube flange bolts (14) 36 to 40 lb.in. (4.1-4.5 Nm). |
| (9) | Torque the vent tube flange bolts (1) 24 to 36 lb.in. (2.7-4.1 Nm). Install safety cable (PWC05-344) or lockwire. |
| (10) |
Torque the coupling nuts on vent tubes (7 and 10) 90 to 100 lb.in. (10.1-11.2 Nm)
and install safety cable or lockwire .
NOTE: Support elbow (13) with a wrench while torquing the coupling nuts.
|
| (11) | Attach filler cap cable (12) to the engine mount pad with bolt (17) . Torque bolt 425 to 475 lb.in. (48-54 Nm) and install lockwire. |